Kawasaki Kx500 Service Manual Repair 1988-2004 KX 500

KX125
KX250
KX500
Motorcycle
Service Manual
This quick reference guide will Issist you
in locating e desired topic or procedure .
Bend the pages back to match the black
tab of the desired chapter number wi th
the black tab on the edge at each table
of contents page .
Refer to the sectional table of contents for
the exact pages to locate the specific topic
required.
Quick Reference Guide
General Information
Fuel System
Cooling System
Engine Top End
Engine Right Side
Engine Removal/Installation
Engine Bottom EndlTransmission
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Electrical System
II'
Appendix
Kawasaki
KX125
KX250
KX500
Motorcycle
Service Manual
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
'C
DC
F
' F
It
9
h
L
LIST OF ABBREVIATIONS
ampere(s) Ib Pound(s)
after bottom dead center m meter(s)
alternating current min minute(s)
after top dead center N newton(s)
before bottom dead center Pa PascaHs)
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot. feet
gram(s)
houris)
liter(s)
WARNING
CONTAINS
ASBESTOS
a_thing ltlbtsloo
dun It dlngtl'OUS
lon .. ltII
PS horsepower
psi pound(s) per square inch
r revolution
rpm revolution(s) per minute
TDC top dead center
TIR total indicator reading
V valtls)
W watUsl
n ohm(s)
This warning may apply to any of the follow-
ing components or any assembly containing
one or more of these components:-
Brake Shoes or Pads
Clutch Friction Material
Gaskets
Insulators
SAFETY INSTRUCTIONS
- Operate if possible out of doors or in a well
ventilated place.
-Preferably 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.
-If possible, dampen before cutting or drilling.
-Campen dust and place it in properly 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
information to make it useful to the owner
who desires to perform his own basic main-
tenance and repair work. A basic knowledge
of mechanics, the proper use of tools, and
workshop procedures must be understood in
order to carry out maintenance and repair
satisfactorily. Whenever the owner has insuf-
ficient experience or doubts his ability to do
the work, aU adjustments, maintenance, and
repair should be carried out only by qualified
mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work
carefully in a clean area. Whenever special
tools or equipment are specified, do not use
makeshift tools or equipment. Precision meas
urements can only be made if the proper instru
ments are used, and the use of substitute tools
may adversely affect safe operation.
We recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual.
To get the longest life out of your motor
cycle:
- Follow the Periodic Maintenance Chart in the
Service Manual.
-Se alert for problems and nonscheduled
maintenance.
-Use proper tools and genuine Kawasaki
Motorcycle parts. Special tools, gauges. and
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.
-Follow the procedures in this manual care
fully. Don't take shortcuts.
- Remember to keep complete records of main
tenance and repair with dates and any new
parts installed.
............ ............. ....... .... ... . .. .. ...... . ...........
How to Use this Manual
. ................... ................... ...................... .
In preparing this manual , we divided the
product into its major systems. These systems
became the manual's chapters. All information
for a particular system from adjustment
through disassembly and inspection is located
in a single chapter.
The Quick Reference Guide shows you all
of the product' s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located
in the General Information chapter. The chart
gives a time schedule for required maintenance
operations.
If you want spark plug information. for ex-
ample, go to the Periodic Maintenance Chart
first. The chart tells you how frequently to clean
and gap the plug. Next, use the Quick Reference
Guide to locate the Electrical System chapter.
Then, use the Table of Contents on the first page
of the chapter to find the Spark Pfug section.
Whenever you see these WARNING and
CAUTION symbol s. heed their instructionsl
Always follow safe operating and maintenance
practices.
I WARNING'
oThis warning symbol identifies special i"struc .
tions or procedures which, if not cOlTectly
followed, coukt result In personal injury, or
loss of life.
oThis caution symbol identifies special instruc-
tions or procedures which. If not strictly ob-
served. could result in damage to or destruc-
tion of equipment.
This manual contains five more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of
information.
NOTE
oThis note symbol indicates 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 , -,
D
General Information
Table of Contents
Before Servicing ... . ......... _, _ .. . ..... . .. .... . ... .... .... _,_... ... . . .. ... . .. . .. .. . 1-2
Model Identification ...... . ...... ................. .. .. ........................... ..... '-4
General Specifications ....... . .. . ............... . .......... .. ............ . .......... '-7
Periodic Maintenance Chart ...................... ........... . ........ _, ........ , - 13
Torque and Locking Agent ... .. .................. ...... . ......... . .. . ........ . .. '14
Cable Routing .. . ... ........................ , .......... ................................. 1-18
12 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, warnings, and detailed des-
criptions have been included wherever necessary. Nevertheless, even a detailed account has
limitations, a certain amount of basic knowledge is also required for successful work.
Especially note the foBowing:
(1) Dirt
Before removal and disassembly I clean the motorcycle. Any dirt entering the engine or other
parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, be-
fore installing a 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 pat-
tern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when
loosening the bolts, nuts. or screws, first loosen all of them by about a quarter of tum and then
remove them.
Where there is a tightening sequence indication in this Service Manual . the bolts. nuts.
or screws must be tightened in the order and method indicated.
(3) Torque
The torque values given in this Service Manual should always be adahered to. Either too
linle or too much torque may lead to serious damage. Use a good quali ty, 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 what may be caus-
ing the problem. Whenever tapping is necessary. tap lightly using a wooden or plastic faced
mallet. Use an impact 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 piece 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 manufac-
turer and container directions regarding the use of any solvent.
(7) Gasket, O-ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around
the gasket should be free of foreign maner and perfectly smooth to avoid oil or com-
pression leaks.
(8) Uquid Gasket. Non-permanent Locking Agent
Follow manufacturer' s directions for cleaning and preparing surfaces where these compounds
will be used. Apply sparingly. Excessive amount s 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 Nt Seal !Blue).
(9) Press
A part installed using a press or driver. such as a wheel bearing, should first be coated
with oil on its outer or inner circumference so that it will go into place smoothly.
('0) 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) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
Seals should be pressed into place using a surtable driver. which contacts evenly with the side of
the seal, until the face of the seal is even with the end of the hole.
(1 2) Seal Guide
A seal guide is required for certain oi l 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 tips
to reduce rubber to metal frict ion.
(3) 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.
114) Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks them.
11 5) Lubrication
Engine wear is generally at its maximum while t he 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 recommendations before using such special lubricants.
1161 Electrical Wires
All the electrical wires are either single-color or two-color and, with only a f ew exceptions, must be
connected to wires of the same color. On any of the two-color wires there is a greater amount of one
color and a lesser amount of a second color, so a two-color wire is identified by first the primary color
and then the secondary color. For example, a yellow wire with thin red strips is referred to as a "yel-
low/red" wire; it would be a "red/yellow" wire jf the colors were reversed to make red the main color.
Wire (cross-sectionl Name of Wire Color
Red
Wire strands
Yellow/red
Yellow
Red
117) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed. These replacement parts wi ll be damaged or lose t heir 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
(19) Service Data
Deterioration Seizure
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 t he usable limits. If the measurement shows excessive wear or dete-
norated performance. replace the damaged parts.
1-4 GENERAL INFORMATION
Model Identification
KX 125 F1 Left Side View
KX125-Fl Right Side VIew
KX250 F 1 left Side View
KX250-F 1 Right Side View
KX500-Dl Left Side View
KX500-01 Right Side View
General Specifications
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight : Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark plug
Port timing: Inlet
Scavenging
Exhaust
Lubrication system
Drive Train:
Primary reduction system:
Type
Open
Close
Open
Close
Open
Close
Reduction ratio
Clutch type
Transmission: Type
Gear ratios: 1 st
2nd
3rd
4th
5th
6th
Final drive system: Type
Reduction ratio
Overall drive ratio
Transmission oil: Grade
Viscosity
Capacity
KX12S-F1
2150 mm
815 mm
1170 mm
1465 mm
380 mm
950 mm
86.5 kg
45.5 kg
48.5 kg
8.6 L
2-stroke, single cylinder, crankcase reed valve
Liquid.cooled
56.0 x 50.6 mm
124 mL
8.39:1
25.6 kW 134.8PSI @1 1500 rl min Irpml
22.9 N-m12.33 kg-m, 16.9 h-Ibl @ 9500 rl min
(rpm)
Carburetor, KEIHIN PWK 35
Primary kick
COl
13
0
BTDC @11000r/min (rpm)
NGK 810EG O(Q)NGK BR10EG
Full open
61' B8DC
61' ABDC
95.5' 88DC
95.5' A8DC
Petrol mix (32: 1)
Gear
3.5001631181
Wet, multi disc
6-speed, constant mesh, return shift
2.1 42 1301141
1.7141241141
1.400 1281201
1. 1811261221
1.041 1251241
0.9201231251
Chain drive
3.9161471121
12.611 @Topgear
SE class
SAE 10W30 or lOW40
0.65 L
on next page.!
18 GENERAL INFORMATION
Item
Frame:
Type
Steering angle
Caster trake angle)
Trail
Front tire: Make/Type
Size
Rear tire: Make/Type
Size
Front suspension: Type
Wheel travel
Rear suspension: Type
Wheel travel
Brake type: Front and Rear
Effective disc diameter:
Front
Rear
KX125 Fl
Tubular, single down tube
45 to Bither side
27'
122 mm
DUNLOP K490 IE) DUNLOP K990. Tube type
801100 - 21 51M
DUNLOP K595 IE) DUNLOP K990. Tube type
10011 00 - 1 859M
Telescopic fork lAir fork)
300 mm
Swing arm IUnHrakl
330 mm
Single disc
220 mm
190 mm
Speci fications subject to change without notice. and may not apply to every country.
o : Canadian model
() : European model
I(b : U. K. model
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight: Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark plug
Port timing: Inlet
Scavenging
Exhaust
Lubrication system
Drive Train:
Type
Reduction ratio
Clutch type
Transmission: Type
Gear ratios:
Open
Close
Open
Close
Open
Close
15t
2nd
3rd
4th
5th
Reduction ratio
Overall drive ratio
Transmission oil: Grade
Viscosity
Capacity
KX2S0-Fl
2200 mm
815 mm
1205 mm
1500 mm
370 mm
960 mm
96.5 kg
50 kg
52 kg
9.9 L
2-stroke, single cylinder, piston reed valve
Liquid-cooled
67.4 x 70.0 mm
249 mL
10. 1: 1
37.5 kW 151PSI @8000 rl min Irpml
46.1 N-m 14.7 kg-m, 34.0 ft-Ibl @7500 rl min Irpml
Carburetor, KEIHiN PWK 39
Primary kick
CDI
13
0
BTOC @6000 rl min (rpm)
NGK B9EG <QI NGK BR9EG
Full open
59.5' BBDC
59.5' ABDC
90' BBDC
90' ABDC
Petrol mix (32: 1)
Gear
2.750 1551201
Wet, multi disc
2. 133 1321151
1.687 1271161
1.3881251181
1. 136 1251221
1.000 1241241
Chain drive
3.3571471141
9.232 @Top gear
SE class
SAE 10W30 or lOW40
0.8 L
(Continued on next page I
' -'0 GENERAL INFORMATION
Item
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire: MakelType
Size
Rear tire: Make/Type
Size
Wheel travel
Wheel travel
Effective disc diameter: Front
Rear
KX250-F'
45
0
to either side
28'
129 mm
DUNLOP K490 K990. Tube type
80/100-21 51M
DUNLOP K595 K990 Tube type
110/100-1864 M
Telescopic fork (Ai r fork)
300 mm
Swing arm (uni-trakl
330 mm
Single disc
220 mm
190 mm
Specifications subject to change without notice. and may not apply to every country.
: Canadian Model
1Di : U.K. Model
(E): European Model
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight: Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburet ion system
Starting system
Ignition system
Ignition timing
SparK plug
Port timing: Inlet
Scavenging
Exhaust
Lubrication system
Drive Train:
Type
Reduction ratio
Clutch type
Transmission: Type
Gear ratios:
Open
Close
Open
Close
Open
Close
151
2nd
3rd
41h
5th
Reduction ratio
Overall drive ratio
Transmission oil : Grade
Viscosity
Capacity
KX500-01
2200 mm
8 15 mm
1205 mm
1500 mm
370 mm
960 mm
100 kg
52 kg
54 kg
9.9 L
2-stroke. single cylinder. piston reed valve
liquid-cooled
86.0 x 86.0 mm
499 mL
7. 1: 1
45.6 kW 162 PSI @7000 rl min Irpm)
64.7 N-m 16. 6 kg-m. 47.7 ft -I b) @6000 rlmin Irpm)
Carburetor. KEIHIN PWK 39
Primary kick
CD)
17 BTDC @6000 rlmin !rpm)
NGK B8ES iO@ NGK BR8EG
Full open
60 BBDC
60 ABDC
90 BBDC
90 ABDC
Petrol mix (32: 1)
Gear
2.538 (66126)
Wet . mul t i disc
5-speed. constant mesh. return shift
2.000 (32116)
1.450 (29120)
1.181 (26122)
0.954 (21122)
0.791 (19124)
Chai n drive
3.357147114)
6.746 @Top gear
SE class
SAE 10W30 m 10W40
0.8 L
(Conunued on nelCt page)
1- 12 GENERAL INFORMATION
Item
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front type: Type
Rear type:
Size
Type
Size
Wheel travel
Wheel travel
KX500-01
Tubular. single down tube
45 to either side
28
129 rnm
8RIDGESTONE M23 <E> DUNLOP K990. Tube
type
80/100- 21 51 M
BRIDGESTONE M22 <E> DUNLOP K990. Tube
type
110/ 100-18 64M <E> 120/ 100-1868 M
Telescopic fork: (Air fork)
300 mm
Swing arm IUni-trak)
330 mm
Single disc
220 mm
Rear 190 mm
Specifications subject to change without notice, and may not apply to every country.
C> : Canadian model
() : European model
o : U. K. model
GENERAL INFORMATION 1-1 3
Peri odic Maintenance Chart
FREQUENCY
Each Every Every Every A,
OPERATION
race 3 races 5 races 10 races required
Clutch-adjust

Clutch and friction plates-<:heck t

R
Throttle cable-adjust

Spark plug--clean, gap t

R
Air cleaner element-clean

Air cleaner element- replace Damaged
Carbu retor - inspect! ad ju st

w
Transmission oil-chan!le

z
Piston and piston ring-clean/ check t

R
'"
Cylinder head, cylinder and exhaust
z

w valves- inspect
Muffler--clean/check t

Silencer wool.-change

Small end beariM-check t

R
Kick oedal and shift oedal--clean

Exhaust pipe O.rina-replace

Engine sprocket--check t

Coolant--check t

R
"-
Radiator hoses, connections-check t

Brake adjustment--check t

Brake wear--check t

Brake fluid level--check t

Brake fluid--chanQe Every 2 vears
Brake master cylinder cup and dust
Every 2 years
sealreplace
Brake caliper piston seal and dust sealreplace Every 2 years
Brake hose and pipereplace Every 4 years
Spoke tightness ana rim runout check t

Drive chain-ad' ust

Drive chain-lubricate

Drive chain wear-check t

'"
Chain slipper and guidereplace Damaged -
t:l
Front fork - inspect/clean

I I I
0:
:I: Front fork oil --change , 51 time after 2 races, then every 5 races
u
Nuts, bolts, fasteners-check t
I I I I

Fuel hose- replace Everv 4 '\Iears
Fuel system--clean

Steerina play-check t

Steering stem bearing-grease

Rear sprocket-check t

General lubrication-perform

Wheel bearinc-<lrease

Swing arm and Uni -trak linkage pivots- check t

Swing arm and Uni -trak linkage pivots-grease

Rear shock oil--replace , st time after 2 races, then every 5 races
t Replace, add, adj ust or torque if necessary. R : Replace
GENERAL INFORMATION 1- 15
Torque
Fastener
N-m kg-m It-Ib
Remarks
Engine Right Side:
External Sift Mechanism
Return Spring Pin (KX 125, 250) 22 2,2 16,0 L
IKX500) 20 2,0 14,5 L
Clutch Spring Bolts 9, 3 0, 95 82 in-Ib
Neutral Set Lever Bolt 9,8 1,0 87 in-Ib
Clutch Hub Nut IKX 125) 78 8 58 L
IKX250, 500) 98 10 72
Primary Gear Nut (KX 125) 59 6,0 43
Kick Guide Mounting Bolts 9,8 1,0 87 in-Ib L
Exhaust Valve Advancer
Shaft Mounting Bolts 3,9 0.4 35 in-Ib
Exhaust Valve Advancer Shaft
Plug Screw 2,0 0,2 17 in-Ib
Clutch Cover Bolts (KX 125, 250) 9,8 1,0 87 in-Ib
Right Engine Cover Bolts 9.8 1,0 87 in-Ib
Exhaust Valve Operating Lever Nut
IKX125)' 8. 3 0,85 74 in-Ib
IKX250) 9.8 1.0 87 in-Ib
Exhaust Valve Operating l ever Bolt
IKX500) 9,8 1.0 87 in-Ib
Engine Removal/lnstallation:
Swing Arm Pi vot Shaft Nut 81 8.3 60
Engine Mounting Nuts 25 2.6 19,0
Engine Bracket Mounting Nuts 25 2.6 19,0
Engine Bottom End/Transmission:
Transmission Oil Drain Plug 20 2.0 14, 5
Output Shaft Bearing Retaining
Bolts 5,9 0,6 52 in-Ib
Drive Shaft Bearing Retaining
Bolts
9,8 1.0 87 in-Ib
Shif t Drum Bearing Retaining Bolts 9,8 1.0 87 in-Ib
Shift Drum Operating Plate 80lt 22 2. 2 16.0
Crankcase Bolts 9,8 1,0 87 in-I b
WheelsfTlres:
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 tess
than 1.5 than 0 . 15 than 13 in-Ib
Final Drive:
Rear Sprocket Bolts 29 3 22.0
Torque
Fastener
N-m kg-m It-Ib
Remarks
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 Lever Pivot Locknut 5.9 0 .6 52 in-tb
Brake Disc Mounting Screws (Front,
Rear) 9.8 1.0 87 in-tb
Caliper Bleed Valves (Front. Rear) 7.8 0 .8 69 in-Ib
Brake Pedal Mounting Bolt 8. 8 0.9 78 in-Ib L
Suspension:
Front Fork Clamp Bolts (Upper, Lower) 20 2.0 14. 5
Front Fork Oil Drain Screw - - - L
Front Fork Cylinder Valve Assembly 54 5. 5 40 L
Swing Arm Pivot Shaft Nut 78 8.0 58
Rear Shock Absorber
Mounting Bolts 34 3.5 25
Tie-Aod Mounting Nuts (Front. Rear) 81 8.3 60
Rocker Arm Bracket Mounting Botts 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 IKXl 25) 22 2.2 16.0
IKX250) 27 2.8 20
Flywheel Nut IKX 500) 78 8 58
Stator Mounting Screws 5.9 0 .6 52 in-Ib
Magneto Cover Bolts 9.8 1.0 87 in-Ib
Sperk Plug 27 2.8 20.0
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts
and nuts. Use this table for only the bolts and nuts which do not require a specifi c torque value.
All of t he val ues are for use with dry solventcJeaned threads.
General Fasteners
Threads diameter Torque
(mm) 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
KX 125:
KX250:
1. Throttle Cable
2. Brake Hose
3. Clutch Cable
4. Ignition Coil
5. Stator lead
1. Throttle Cable
2. Clutch Cable
3, Brake Hose
4. Stator Lead
5. Radiator Breather Hose
KX500:
1. Ignition Coil
2. Throttle Cable
3. Radiator Beather Hose
4. Stator Lead
FUEL SYSTEM 2-1
Fuel System
Table of Contents
Exploded View .................... ..... , .. ". _._ ...... . ... . .... .. . . _. _. .. . . .. .... 2-2
Specifications ..................... . .................... _,_ . .. " ... ........ ,..... 2-4
Special Tools ....................................................... .. ............ 26
Throttle Grip and Cable ................. ' .............. ....... .. . _, _. ........... 2-7
Throttle Grip Free Play Inspection .... " .. .... ........ ............. 2-7
Throttle Cable Adj ustment ........................ " ....... ..... ,. .... 2-7
Throttle Cable Installation Notes ........ . ..... "". . ... .... ......... 28
Throttle Cable Lubrication . ................... ........... ...... . ....... 28
Throttle Cable Inspection ........ . .. ... .... .. . .. .. .. .. ... ............. 2-8
Carburetor ................. ............. ... .................. .... ...... ... . .. ...... 2 9
Idle Speed Inspection .. . ...... . ...... .................. .... ............. 2 9
Idle Speed Adjustment . . .................... .. ....... ..... .... ...... ... 2-9
Service Fuel level Inspection . ..... . ... . .. .. .. .... ... ... ..... ...... ... 2-9
Service Fuel level Adjustment .......... . .. ........................ 2-10
Fuel Syst em Clean . .. ...... . .......... . .......... ........... .... .. .. ... 2-11
Carburetor Removal .. . .... . .. . ........... ...... ... .. .. ............ . ..... 2-11
Carburetor Installation Notes ....... ........... ... . . .......... .. ..... 2- 12
Carburetor Disassembl y . .............. _ .. ....... .. ......... . . ___ . ... .. 2-13
Carburetor Assembly Notes ......... ..................... . .. ..... 2- 14
Carburetor Cleaning . ........ . . .......... _ . ........... ... ..... . ____ ..... . 2-14
Carburetor Inspection ........ _ ................. _ ... ..... . ... ___ __ . ... . . 2-14
Air Cl eaner .... ... .... . .... . ... . .... . .. . ....... . ........ . ..... . ... . ..... ..... . ..... 2-15
Air Cleaner Housing Removal .... . ... ........ ...... ....... .. .. ...... 2-15
Air Cleaner Housing Installation Notes .... .... . ....... .... . ...... 2-15
Air Cleaner Element Removal . ................. .............. . ....... 215
Air Cleaner Element Installation Notes ... ... . ... ...... ... . ..... . 2- 16
Air Cleaner Element Cleaning and Inspecti on .. . .... . . ........ 216
Fuel Tank ............... . ............. . .... . ............ . ......... .. ...... . ........ 2-17
Fuel Tank Removal ..... .. ... . .. . ............ . ......... .. . ..... ... .... . .. 2-17
Fuel Tank Installation Notes ... . . . .. . ........... .. .. .. ... .. ... ... .. . 2-17
Fuel Tap Removal ....... .. ... .. ......... . ...... .. . ..... . .. .. . .... . .. .. . 2- 17
Fuel Tap Installati on Notes .. . ........ .. ..... .. . . ..... . .. .. ... .. ...... 2-17
Fuel Tap Inspection .... . ........ ..... ___ ....... __ _ ........... _ ... ....... 2-17
Fuel Tank Cap Inspection .. . ....... .. .. ... . .. . ........ . .... . ... . ..... 2-18
Fuel Tank and Tap Cleaning ...... ........... .. ........ . ... . . ....... 2- 18
Reed Valve ........ ... ..... ...................................... ... .. ... .. .. .... 2 19
Reed Val ve Removal .................................................... 2 '9
Reed Val ve Installation .. . .................... .......................... 2- 19
Reed Valve Inspection .. ...... .. .... __ . . .. .... ___ ......... . __ . .. ... ..... 2-19
2-2 FUEL SYSTEM
.......
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FUEL SYSTEM 2-3
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87 in-lb)
n -9.8 N-m (1.0 :g,:, 19 ft.lbl
' 25 N-m 12.6 g- T2:
2-4 FUEL SYSTEM
Specifications
KX125'
Item Standard Service Limit
Thronle Grip Free Play 2 - 3 mm - - -
Carburetor Specifications:
Make/type KEIHIN PWK35 - - -
Main jet 148 - - -
Throttle valve cutaway 6 -
- -
Jet needle R2071J - 3 -
- -
Jet needle clip position 3rd groove from the top - - -
Slow jet 62 - - -
Air screw 11h (turns out)
Service fuel level 1.0 1 mm - --
(below the bottom edge of the carbo body)
Bore Center 32 mm - - -
Float height 16 , mm
- - -
Air Cleaner Element Oil: 2-stroke racing oil or high-
quality foam-air filter oil - --
Reed Valve:
Reed warp - - - 0.2 mm
KX250'
Itam Standard Service Limit
Throttle Grip Free ptay 2 - 3mm - - -
Make/type KEIHIN PWK39 -
-
-
Main jet 172 - - -
Throttle valve cutaway 7 -
-
-
Jet needle R1368J - 3 - - -
Slow jet 52 - - -
Air screw 1 1/2 (turns out)
- - -
Service fuel level 1.0 1 mm - - -
Bore Center 34 mm - - -
Float height 16 1 mm - - -
Air Cleaner Element Oil : 2 stroke racing oil or high
quality foamair filter oil - --
Reed Valve:
Reed warp
- -- 0.2 mm
FUEL SYSTEM 2-5
KX500' .
Throttle Grip Free Play 2- 3mm - --
Make/type KEIHIN PWK39 - - -
Main jet 175 -
- -
Throttle valve cutaway 7 - - -
Jet needle R1369N-3 - - -
Slow jet 62 - - -
Air Screw 1 112 (turns out)
Service fuel level 1.0 1 mm - --
(below the bottom edge of the carb. body)
Bore Center 34mm -
- -
Float height 16 1 mm -
- -
Air Cleaner Element Oil : 2-stroke racing oil or high-
quality foam-air filter oil
Reed Valve:
Reed warp - - - 0. 2 mm
2 6 FUEL SYSTEM
............ ... ............. ... ... ... ... ....................
Special Tools
............ ... ... ... .......... .. .. . .. .. . .. . . ...............
Along with common hand tools, the following
more specialized tools are required for complete
fuel system servicing.
Fuel Level Gauge: 57001 122
Pressure Cable Luber: K56019-02 1
Throttle Grip and Ca ble
If the throttle grip has excessive free play due to
cable stretch or misadjustment, there will be a delay in
throttle response. Also, the thrott le valve may not open
fu lly at full throttle. On the other hand, if the throttle
grip has no play, the throttle wil l be hard to control,
and the idle speed wi ll be erratic. Check the throttle
grip play periodicall y 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 Pla y Inspection
- Check throttle grip free play by lightl y turning the
throttle grip back and forth.
A. Adjuser
B. l ocknut
C. Throttle Grip
D. Throttle Grip Free Play
Throttle Grip Free Ptay
2 - 3mm
* If the thrott le grip free play is improper, adj ust the
thrott le cable.
Throttle Cable Adjustment
- loosen the locknut at the upper end of the throttle
cable.
- Turn the adjuster unti l the proper amount of thrott le
gri p free play is obtai ned.
FUEL SYSTEM 2-7
A. Adjuster C. Throttle Grip Free Play
B. locknut
- Tighten the locknut.
* If the throttle grip free play cannot be adjusted
with the adjuster at the upper end of the throttle
cable use the cable adjuster at the carburetor.
oPull the boot off of the carburetor top. Make the
necessary free play adjustment at the lowe r cable
adj uster, tighten the locknut, and install the boot.
A. Locknut
B. Adjuster
- Turn the handlebar from side to side while idli ng the
engi ne. If idle speed va ries, the thrott le cable may
be poorly routed or it may be damaged.
I WARNING'
oOperatton with an improperly adjusted, incOfTectty
routed, Of damaged cable cook! resutt in an un-
saf e riding condition.
2-8 FUEL SYSTEM
Throttle Cable Installation Notes
- Install the throttle cable in accordance with the
Cable Routing section in the General Information
chapter.
- After the installation, adjust the cable properly.
I WARNING'
o()peration with an Inconectty routed or improperly
adjusted cable could result in an unsafe riding
condition.
Throttle Cable Lubrication
Whenever the cable is remolled, and in accordance
with the Periodi c Maintenance Chart (see General
Information chapter), do the foll owing.
' Apply a thin coating of grease to the cable upper end.
Cable lubrication
1. Apply grease.
' lubricate the cable with penetrating rust inhibitor
through the Pressure Cable Luber (special tool).
Cable Lubricatloo
1. Cable 2. Pressure Cable Luber: K56019-021
Throttle Cable Inspection
- With the throttle cable disconnected at both
ends, the cable should move freely within the cable
housing.
Cab'e Inspection
1. Cable
* If cable movement is not free after lubricating. if
the cable is frayed, or if the housing is kinked,
replace the cable,
Carburetor
..................... .........................................
Since the carburetor regulates and mixes the fuel
and air going to the engine, there are two genera l
types of carburetor trouble: too rich a mixture (too
much fuel), and too lean a mixture (too little fuel) ,
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 a lso alter the fuel
to air ratio.
Idle Speed Inspection
- Start the engine and warm it up thoroughly.
- With the engine idling, turn the handlebar to both
sides.
-I f handlebar movement changes the idl e speed, the
throttle cable may be improperly adjusted or
incorrectly routed, o r it may be damaged. Be sure
to correct any of these conditi ons before riding (see
Cable Routing in the General Information chapter).
[ WARNING'
oOperatlon with an imp.-operly adjusted. incorrectly
routed, or damaged cable could result in an un-
safe riding condition.
- Check idle speed.
* Adjust it as needed.
Idle Speed Adjustment
- Start the engine and warm it up thoroughly.
- First tum in the ai r screw until it seats lightly,
and back it out 1 112 turns.
- Tum the idle adjusting screw to obtain the desired
idle speed. If no idle is preferred, turn out the
screw until the engine stops.
A. Idle Adjusting Screw C. Air Screw
B. locknut
FUEL SYSTEM 2-9
- Open and close the throttle a few times to make
sure that the idle speed is as desired. Readjust if
necessary.
Service Fuel Level Inspection
[ WARNING'
oGasoline ls extremefy flammable and can be ex-
plosive under certain conditions. AJways stop the
engine and do not smoke. Make sura the area is
well ventilated and free from any SOl#C8 of flame
or sparks; this lncludes any apptiance with a pilot
!;ght.
- Tum the fuel tap to the OFF position.
- Remove the fuel tank.
- 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
tap to the carburetor using a suitable hose.
- Remove the drain plug from the bottom of the
float bowl, and screw a fuel level gauge (special
tool) into the plug hole.
-Hold the gauge vertically against the side of car-
buretor body so that the "zero" line is several milli
higher than the bottom edge of the carburetor
body.
-Tum the fuel tap to the ON (X>Sition to feed fuel to
the carburetor.
- Wait until the fuel level in the gauge settles.
- Keeping the gauge vertical, slowly lower the gauge
until the "zero" line is even with the bottom edge
of the carburetor bcxly.
NOTE
000 not tower the "zero" line below the bottom edge
of the carburetor body. tf the gauge is towered and
then raised again. the fuel level measure shows
somewhat higher than the acruat fuel levet. tf the
gauge is lowered too far , dump the fuel out of it
into a suitabie container and start the procedure
over again.
- Read the fuel level in the gauge and compare it to
the specification.
- Tum the fuel tap to the OFF position and remove
the fuel level gauge.
* If the fuel level is incorrect. adjust it.
210 FUEL SYSTEM
Service Fuel level
KX125: 1.0 , mm
KX250: 1.0 1 mm
KX500: 1.0 , mm
1. Fuel level Gauge: 57001-122
2. Service Fuel level
Service Fuel Level Adjustment
I WARNING'
oGasoline 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 8 pilot
light .
-Remove the carburetor, and drain the fuel into a
suitable container.
-Remove the float bowl.
-Drive out the pivot pin and remove the float.
A. Pivot Pin B. Drive out the pin.
-Bend the tang on the float arm very sli ghtly to
change the float height. Increasing the float height
lowers the fuel level and decreasing the float height
raises the fuel level.
Float Height
KX125: 16 1 mm
KX250: 16 1 mm
KX500: 16 1 mm
A. Tang
- Assemble the carburetor, and recheck the fuel
level.
*If the fuel level cannot be adjusted by this method,
the float or the float valve is damaged.
Float Height Measurement-Keihin Carburetor
1
Float height
1. Float bowl mating surface
2. Fl oat valve needle rod (contacted but unloaded)
3. Float
-Place a suitable container beneath the carburetor.
NOTE
-Roat 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
the height with the carburetor upside down.
Fuel System Clean
I WARNING'
oGasoline Is extremely flammable and can be
explosive 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
8 pilot light.
ePl ace a suitable container beneath the carburetor.
eTurn the fuel tap to the OFF position.
eRemove the drain plug from the bottom of the
f loat bowl and check for water or dirt in the fuel.
A. Drain Plug
* If any water or dirt comes out, clean the carbure-
tor, fuel tap and fuel tank (see Fuel Tank).
e Install the drain plug securely.
Carburetor Removal
I WARNING'
oGasoline is extremely flammabla and can be
explosive under certain conditions. Always stop
the engine and do not smoke. Make sure the
area Is well ventilated and free any source of
flame or sparks; this includes any appliance with
a pilot light .
FUEL SYSTEM 2-11
eTurn the fuel tap to the OFF position and pull the
fuel hose off the tap.
ePlace a suitable container beneath the carburetor.
eDrai n the fuel from the f loat bowl by remove the
drain plug.
eloosen the clamps, and remove the carburetor
from the end of the ai r cleaner duct, and then pull
it out of the carburetor holder.
eUnscrew the carburetor cap, and pull out the
throttle valve assembly.
A. Carburetor B. Throttle Valve
olf the throttle valve is not removed from the
cable, wrap it in a clean cloth to avoid damage.
eAfter removing the carburetor, push a clean, lint-
free towel into the carburetor holder and the air
cleaner duct to keep dirt or other foreign material
from entering.
I WARNING'
olf dirt or dust is allowed to pass through into
the carburetor. the throttle mey become stuck.
possibly causing an accident.
olf dirt gets through into the engine. excessive
engine wear and possibly engine damage will
occur .
2 12 FUEL SYSTEM
Carburetor Installation Notes
-Installation is the reverse of removal .
- Being careful not to bend or otherwise damage the
jet needle. Check to see that the t hrottle valve goes
all the way down into the carburetor body, and
slides smoothly.
When installing the carburetor into the carburetor
holder. align the center of the carburetor with the
groove on the holder.
KX125:
KX250. 500
A. Center of the carburetor
B. Groove
eRoute the air vent tube properly .
OAiways keep the tubes free of obstruction,
and maka sure they do not get pinched by the
chain or shock absorber.
- After installing the carburetor. do the foll owi ng.
aTurn the fuel tap to the ON position, and check
for fuel leakage from the carburetor.
I WARNING'
Ofuef ~ from the catburetor Is hazardous.
OAdjust the following items if necessary.
Throttle Cable
Idle Speed
Carburetor Disassembly
. Remove the carburetor.
- Remove the throttle valve assembly and carburetor
cap from the carburetor cable lower end.
Oisassemble t he throttle valve assembly; spring,
retainer, connector.clip. jet needle. circlip and
throttle valve.
A. Spring O. Clip
B. Retainer E. Jet Needle
C. Connector F. Throttle Valve
. Remove the choke knob/starter plunger assembly
from the carburetor.
A. Choke knob/starter plunger Assembly
B. Carburetor
FUEL SYSTEM 213
. Remove the following parts from the carburetor
body,
1. Air Screw
2. Idle Adjusting Screw
3. Slow Jet
4. Main Jet
5. Float Valve
G. Float
7. Pin
8. O-ring
9. Float Bowl
2-14 FUEL SYSTEM
Carburetor Assembly Not es
- Assembly is the reverse of disassembly.
-Clean the disassembled parts before assembling.
- Replace the f l oat bowl O-ring with a new one if it
is deteriorated or damaged.
- Turn in the air screw fully but not
tightly, and then back it out 1 1f2 turns.
A. Ai r Screw
Carburetor Cleaning
I WARNING.
aClean the carburetor in a well-ventilated area,
and take care that there is no s peak or flame
anywhere near the working area: this includes
any appliance with a pilot light . Because of the
danger of highly flammable liquids. do not use
gasoline or low flash-point solvent to clean the
carburetor.
- Make sure the fuel tap is in the OFF position.
- Drain the fuel in the carburetor.
- Remove the carburetor.
- Disassemble the carburetor.
000 not use compressed air on an assembled
carburetor. the float may be deformed by the
pressure.
oRemove as many rubber or plastic parts from the
carburetor as possible before cleaning the car-
buretor with a cleaning solution. This will prevent
damage or deterioration of the parts.
000 not use a strong carburetor cleaning solution
which could anack the plastic parts; instead. use
a mild high flash-point cleaning solution safe for
plasti c parts .
000 not use wire or any other hard instrument
to clean carburetor parts. especially jets. as they
may be damaged.
-I mmerse all the metal parts in a carburetor clean
ing sol ution.
- Rinse t he parts in water.
- When t he pa rts are clean, dry t hem with com-
pressed air.
- Blow t hrough the air and fuel passages with com-
pressed air.
- Assemble the carburetor, and install it on the motor-
cycle.
Carburetor Inspection
I WARNING.
oGasoline is extremely flammable and can be ex-
plosive under certain conditkms. Stop the engine.
Do not smoke. Make sure the area is well -
ventilated and free from any source of flame or
sparks; this includes any appUance with a pilot
light.
- Remove the carburetor.
Before disassembling the carburetor, check the
fuel level (see Fuel level Inspection).
* If the fuel is incorrect, inspect the rest of the
carburetor before correcting i t.
- Pull the throttle cable to check that the throttle
valve moves smoothly and returns by spring pres-
sure.
* If the t hrottle valve does not move smoothly,
replace the carburetor.
- Clean the carburetor.
- Remove the float valve needle.
- Check the float valve needle 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 fully by spring tension,
replace the valve needle.
Float Valve We.
Push and releue
1. Rod 3. Valve Needle Wear
2. Valve Needle
- Remove the slow jet
- Check the slow jet for any damage.
*If the slow jet is damaged, replace it with a new
one.
- Remove the throttle valve and jet needle.
- Inspect the outside of the throttle valve for scratches
and abnormal wear.
* If it is badly scratched or worn, replace the throttle
valve.
- Inspect the inside of the carburetor body for these
same faults.
* If it is badly scratched or worn, replace the entire
carburetor.
- Check the jet needle for wear.
'* A worn jet needle should be replaced.
- Disassemble the carburetor, and dean the fuel and
air passages with a high-flash point solvent and
compressed air.
FUEL SYSTEM 2-15
Air Cleaner
.. .......... ............................ .... ..................
Air Cleaner Housing Removal
- loosen the air cleaner duct clamp.
- Remove the following parts.
Seat
Side Covers
Si lencer
Rear Fender
Rear Flap
Rear Frame
-Remove the air cleaner housi ng.
Air Cleaner Housing Insta/larion Notes
- Installation is the reverse of removal.
- Tighten the rear frame mounting bolts to the speci-
fied torque.
rlghtening Torque
25 N-m 12.6 kg-m. 19.0 ft4b1
Air Cleaner Element Removel
- Remove the seat.
- Remove the wing bolt and pull out the element.
A. Air Cleaner Element
B. Wing Bolt
2-16 FUEL SYSTEM
Ai, Cleaner Element Installation Notes
-I nstallation is the reverse of removal.
- When installing the element, coat the lip of the
el ement with a thi ck l ayer of all purpose grease to
assure a complete seal against the air cleaner ele-
ment base. Also, coat the base where the lip of the
element fits.
A. Crease
Air Cleaner Element Cleaning and Inspection
NOTE
aln dusty areas, the element should be cleaned more
frequently than recommended interval.
oAfter ritfmfl through rain or on muddy roads, the
element should be cleaned immediately.
oSince repeated cleaning opens the pores of the eltr
rmmt, replace it with 8 new one in accordance with
the Periodic Maintenance Chan. Also, if there is 8
break in the elermJnt material or any other damage
to the element, replace the element with 8 new one.
I WARNING I
0CIean the etement i'l a wei-ventilated area, and
take care that there .. no sparts or flame any-
where ,... the working area; thiI Indudes any
._ with plot ight.
0-.... of the dang of highly flammable liquids.
do not use galOlne 01 a tow flash-point solvent
to ~ the element.
Remove the air cleaner element. and separate the
element from the element frame.
A. Element B. Frame
Clean the element in a bath of a high flash-point
solvent. and squeeze the element dry.
Check all the parts of the element for visible damage.
*If any of the parts of the element are damaged,
replace them.
After cleaning. saturate the element with 2-stroke
racing oil or high-quality foam-air-filter oi l, 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
Fuel Tank
Fuel Tank Removal
- Remove the seat.
-Turn the fuel tap to the OFF position.
-Pul l the fuel hose off the fuel tap.
I WARNING'
oG8501lne Is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area ls
well ventilated and free from any source of flame or
sparks; this includes any appiance wfth a pilot light.
- Unhooks the rubber band, and remove the fuel tank
mounting bolts.
-Remove the fuel tank .
A. Mounting Bolts B. Rubber Band
-Drain the fuel tank.
Fuel Tank Installation Notes
- Check the rubber dampers on the frame top-pipe and
fuel tank.
A. Dampers
FUEL SYSTEM 2- 17
* If the dampers are damaged or deteriorated, replace
them.
- Be sure the fuel hose is damped to the fuel tap to
prevent leaks.
- Insert the fuel tank breather hose outlet end into the
number plate hole. (see Hose Routing in the General
information chapter).
A. Fuel Tank Breather Hose
B. Number Plate Hole
Fuel Tap Removal
- Remove the fuel tank and drai n it
_ Remove the mounting bolts and take out the fuel
tap.
Fuel Tap Installation Notes
- Install ation is the reverse of removal.
- Be sure the O-ring is in good condition to prevent
leaks.
- Be sure to clamp the fuel hose to the tap to prevent
leaks.
Fuel Tap Inspection
- Remove the fuel tap.
- Check the fuel tap filter screen for any breaks or
deterioration.
2-18 FUEL SYSTEM
Fuel Tap
1. D-ring 2. Filter Screen
'* If the fuel tap screen has any breaks or is deterio-
rated. it may allow dirt to reach the carburetor,
causing poor runni ng_ Replace the fuel tap.
* If the fuel tap leaks. or allows fuel to flow when it
is at OFF position, replace the damaged D-ri ng.
Fuel Tank Cap -Inspection
Remove the fuel tank cap.
Inspect the gasket on the tank cap for visible
damage.
* Replace the gasket if it is damaged.
Remove t he breather hose and check to see that
the hose is not clogged.
* If it is clogged, blowout the breather hose with
compressed air.
Fuel Tank and Tap Cleaning
- Remove the fuel tank and drain it.
Pour some high flash-point solvent into the fuel tank
and shake the tank to remove dirt and fuel deposits.
WARNING I
<>Clean the tank In a well-ventilated area, and take
care that there Is no sparks or flame anywhere
ne.r the working ara . Because of the danger of
highly flammable liquids. do not use gasoline or
low flash-point solvent to clean the tank.
- Pour the solvent out of the tank.
- Remove the fuel tap from the tank by taking out the
bolts.
- Clean the fuel tap filter screen in a high flash-point
solvent.
* Pour high flash-point solvent through the tap in all
lever positions.
- Dry the tank and tap with compressed air.
-Install the tap in the tank.
-I nstall the fuel tank.
Reed Valve
Reed Valve Removal
- Remove the carburetor from the carburetor holder
and air cleaner duct.
-Remove the carburetor holder mounting bolts, and
move the holder rearward.
- Take the reed va lve out of the cylinder.
-For KX125 model; remove the reed valve out of
the crankcase.
RefJd Valve Installation
- Installation is the reverse order of removal (see car*
buretor Installation Notes).
- Tighten the carburetor holder mounting bolts to
the specified torque.
Tightening Torque
9 .8 N-m (1 .0 kgm. 87 in-Ibl
Reed Valve Inspection
- Inspect the reeds for cracks, folds, or other visible
damage .
... If there is any doubt as to the condition of a reed,
replace the reed va lve part with a new one .
... 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 Valve Holder
FUEL SYSTEM 2-19
... If anyone of the clearance measurements exceeds
the service limit. replace the valve part with a
new one.
Reed Warp
Service Umit: 0 .2 mm
COOLING SYSTEM 3-1
Cooling System
Table of Contents
Exploded View ........... . .. . .. . ... . .... . .... ... ....... ".................... . ..... 32
Specifications ........ .. .. .. . .... .... . ...... ... . ...... . ,' ", ... ... . .. ...... .... ... 3-5
Special Tool . .. ....... . . ...... .... ....... .. ... . . .. ..... ...... .. . .......... ".. ........... 3-5
Coolant ................. ..... .. ...... . .. .......... ......... ", .. .... ...... .... . .. ... ... 3-6
Coolant Inspection ..... .......... . , . ...... . .. ... ....... . . , .. ..... ,...... .. ..... 3-6
Coolant Change ....... ........ ..... , .. ,' ... , .............. .... ,.,. ,..... . ....... 3-6
Air Bleeding .......................... , ... ",..... ......... ................ .. .... 38
Cooling System Pressure Testing .................. . ................ . . . ... 38
Cooling System Flushing ... ............. ............ .................. .. .... 39
Disassembly and Assembly Precautions ...................................... 39
Water Pump ............ ........................ .. .... . ......... ... .. .... . .. ...... .... .. 3-9
Water Pump Cover Removal... ......... .. ......... ... .. .... . ........ ....... 3-9
Water Pump Cover Installation Notes .. .... .. .. ........ .............. . 3- 10
Impeller Removal ... .......................... ........... . .................... 310
Impeller Installation ........................ ........ ...... . ............. ...... 3-10
Impeller Inspection ..... ............................ ............. . ...... ...... 3- 10
Water Pump Shaft Removal ... ....... ......... ............ .. .... .. .. .. . .. 3-10
Water Pump Shaft Installation Notes .. ....... .. .... ...... ....... .. ... . 310
Oil Seal Removal ..................... .... . ..... . ..... ....... .. . ..... ....... . .. .. 3- 11
Oil Seal Installation .. .......... .... ... .... . .. .. ..... ........... ..... ... .. .. .. .. 311
Radiator ....... .. ............... . ......... . .. . .. . ........ ......... .............. .......... 3 12
Radiator Removal . .. .... . ....... ..... .... .. . . ......... . ......................... 3-12
Radiator Installation ................................................ ........... 3- 12
Radiator Inspection .......................................... . ... ..... .. . ...... 3- 1 2
Radiator Cap Inspection .... . .. ...... .. .. .... ...... ....... .. .. .. ........... ... 3-13
Filler Neck Inspection ... ... .. .... .. ... ... ....................... ......... .... . 313
Cooling Hoses, Breather Hose Inspection ......... ...... .. . ............ 313
Cooling Hoses, Breather Hose Installation Notes ... ....... . ......... 3-14
3-2 COOLING SYSTEM
... .. .. .. ..
Exploded ~ i ~ ~
KX125:
KX250:
TEM 3-3 COOLING SYS
3-4 COOLING SYSTEM
KX500:
T1:
T2:
T3:
87 I.-Ibl 9 8
N-m 11,0 k
g
-m'll a ft-Ibl
. (I 5 kg-m, . I 1
5 N-m. 78 in-Ib
(0 9 kg-m. 9 N-m .
COOLING SYSTEM 3-5
Specifications
Item Standard
Coolant:
Type Permanent type of antifreeze for aluminum
engines and radiators
Color Green
Mixed ratio Soft water 50%, Coolant 50%
Total amount: KX125 O.SSl
KX250 1 . 1 l
KX500 1.3l
Radiator:
Cap relief pressure 95 - 125 kPa 10.95 - 1.25 kg/cm
2
,
1S psil
......... ... ...... ........... ...... .. ....... ................
Special Tool
.. . .. .. . ......... " . .. . ....... ... ...........
Bearing Driver Set : 67001 ' 129
3-6 COOLING SYSTEM
Coolant
Check the coolant level each day before riding the
motorcycle. and replenish coolant if the level is low.
Change the coolant in accordance with the Periodic
Maintenance Chart (see the General Information
chapter).
I WARNING'
aTo avoid burns, do not remove the radiator cap
or try to Inspect the coolant level or change
the coolant when the engine Is still hot . Wait
until It cools down.
Coolant Inspection
Coolant Level:
- Situate the motorcycle so that it is perpendicular to
the ground.
- Remove the radiator cap in two steps. Fi rst turn
the cap counterclockwise to the first stop and wait
there for a few seconds. Then push and turn it
further in the same direction and remove the cap.
- The coolant level should be at the bottom of the
radiator filler neck.
NOTE
o Check the level when the engine is cold (room
or ambient temperature),
1. Coolant level 2. Breather Hose
* If the coolant level is low, add the correct amount
of coolant through the filler opening.
Recommended coolant:
Permanent type of antifreeze {soft water and ethyl-
ene glycol plus corrosion and rust inhibitor chemi-
cals for aluminum engines and radiators)
Water and coolant mixture ratio:
1:1 (Water 50%, Coolant 50%)
Total amount
KX125: O.88l
KX250: 1.1l
KX500: 1.3l
CooWrt Deterioration:
- Visuall y inspect the old coolant
* If whitish cotton-like wafts are observed, aluminum
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 cooling system leak. It may be caused byex-
haust gas leaking into the cooling system.
Coolant Change
The coolant should be changed periodicall y to en-
sure long engine life.
Coolant Draining:
I WARNING'
OCoolant on tires will make them slippery and can
cause an accident and Injury, Immediatelv wipe up
or wash away any coolant that spiHs on the
frame, engine or other painted parts.
oSince coolant is harmful to the human bodV. do
not use for drinking.
-Remove the radiator cap.
NOTE
oRemove the radiator cap in two steps. First turn
the cap counterclockwise to the first stop and
wait there for a few seconds. Then push down
and tum it further in the same direction and re
move the cap.
~ - -
A. Radiator Cap
eplace a can tamer under the coolant drain plug. and
drain the coolant from the radiator and engine by
removing the drain plug at the bottom of the water
pump cover. Immediately wipe or wash out any
coolant that spills on the frame, engine, or wheel.
A. Water Pump Cover B. Drain Plug
COOLING SYSTEM 37
For KX250:
ePl ace a container under the drain plug on the right
side of the cylinder a nd drain the coolant by re-
moving the drai n plug.
A. Drai n Plug
FOI KX500:
ePlace a container under the hose fitt ing on the right
side of the cylinder and drain t he coolant by remov-
ing the hose fitting.
A. Hose Fitting
elnspect the old coolant for visual evidence of cor-
rosion and abnormal smell (see Coolant Deterio-
ration).
Coolant Filling:
I
oUse coolant containing corrosion inhibitors made
specifically for aluminum enginas and radiators
in accordance with the Instruction of the manu-
facture's.
oSoft 01 distiUed water must be used with the
antifreeze (see below for antifreeze) in the cooling
system.
3-S COOLING SYSTEM
,:r If hard water I. used in the system, It causes
scale accumulation In the water passages, and
considerably reduces the efficiency of the cool -
Ing system.
The coolant provided when shipping
Type Permanent type antlf'.8ze
Color
Mixed ratio
Fr zlng point
Total amount
for aluminum engln and
radiators
Green
Soft water 50%.
coolant 50%
_35 C I_ 31 F)
KX125 - 0.SSL
KX250 - 1.1L
KX600- 1.3L
-Install the drain plug. Always replace the gasket
with a new one, if it is damaged.
eTighten the drain plug to the specified torque.
Tightening Torque:
KX 125: Pump Cover-15N-m 11 . 5kg-m. l1ft-lbl
KX250: Pump Covef - 15N-m (1.6kg-m, l1ft-lbl
Cylinder - 9N-m (O.9kg-m. 78in-lb)
KX600: Pump Cover - 15N-m 11.6 kg-m.l1ft-lb)
- Fill the radiator up to the bottom of the radiator
filler neck with coolant. and install the cap, turning
it clockwise about " turn.
NOTE
oPour in the coo/ant slowly so that it can expel the
air from the enginfJ and radiator.
oThe radiator cap must be installed in two steps.
First tum the cap clockwise to the first stop. Then
push down on it and tum it the rest of the way.
Radlator flier Neck
(j)
1. Breather Hose 2. Coolant level
eCheck the cooling system for leaks.
the radiator cover.
Air Bleeding
Before putting the motorcycle into operation. any
air trapped in the cooling system must be removed
as follows.
- Start the engine, warm up the engine thoroughly.
and then stop the engine.
_ Remove the radiator cover.
- Remove the radiator cap.
- Check the coolant level after the engine cools
dow-no
* If the coolant level is low, add coolant up to the
radiator filler neck.
- Install the radiator cap.
- Check the cooling system for leaks.
- Install the radiator cover.
Cooling System Pressure Testing
Any time the system slowly loses coolant inspect
for leaks.
I
00uring pressure testing. do not exceed the pres-
sure for which the system Is designed to work.
The maximum preSSU'8 is 125 kPa (1 .25kglcm
2
,
1S psi).
- Remove the radiator cover.
- Remove the radiator cap, and install a cooling sys-
tem pressure tester on the radiator fi ller neck.
NOTE
OWet the adapter cap sealing surfaces with water
or coolant to prevent pressure leaks.
- Build up pressure in the system carefully until the
pressure reaches 125 kPa (1.25 kg/cml, 18 psi).
-Watch the gauge for at least 6 seconds, If the pres-
sure holds steady, the cooling system is all tight.
A. Pressure Tester B. Adapter
- Remove the pressure teste r, replenish the coolant,
and install the radiator cap
* If the pressure drops and no external source is
found, check for internal leaks. Check the cylinder
head gasket for leaks.
Cooling Syst em Flushing
Over a period of t ime, the cooli ng system accu-
mulates rust, scale, and lime in the water jacket and
radiator. When this accumulation is suspected or ob-
served, flush the cooling system. If this accumula-
tion is not removed, it will clog up the water passages
and considerably reduce the efficiency of the cooling
system.
- Drain the cooling system.
- Fi ll the cooling system wi th fresh water mixed with
a flushing compound.
oAlloid the use of a flushing compound which is
harmful to the aluminum engine and radiator.
Carefully follow the instructions suPP'1ed by the
manufacturer of the cleaning product.
_Warm up t he engi ne, and run it at normal operat-
ing tempe rature fo r about ten minutes.
- Stop the engine, and drain the cooling system after
the coolant cools down.
- Fi ll the system with fresh water.
- Warm up the engine and drain the system after the
coolant cools down.
- Repeat the previous two steps once more.
- Fill the system with a permanent type coolant, and
bleed the ai r from the system (see Air Bleeding).
Disass embly and assembly Precautions
- Prior to disassembly of cooling system parts (radi-
ator, pump, etc). wait until the coolant cools down,
and then drain the coolant.
- After assembling and filling the system with coolant,
bleed any air from the system.
COOLING SYSTEM 39
Water Pump
Water Pump Cover Removal
- Drain the coolant (see Coolant Draining).
- Loosen the cooli ng hose clamps, and disconnect the
cooling hoses on t he water pump cover.
- Remove the water pump cover bolts, and remove
the water pump cover.
KX126,
A. Water Pump Cover B. Bolts
KX250:
3-10 COOLING SYSTEM
KX500:
Water Pump Cover Installation Notes
'I nstallation is the reverse of removal.
- Replace the pump cover gasket with a new one.
- Fill the cooling system (see Coolant Fi ll ing).
Impeller Removal
eOrain the cool ant (see Coolant Drai ning),
. Remove the cover bolts and take out the water
pump cover f rom the right engi ne cover wi th t he
cooling hose(s) attached.
- Remove the impeller bolt, and pull out t he impell er
and washer.
A. Impeller B. Boh
Impeller Installation
- Install the impeller onto the water pump shaft, and
tighten the impeller boh to the specified torque.
Tightening Torque:
9.8 N-m 11 .0 kg-m, 87 in-Ibl
Impeller Inspection
Visual ly check the impeller.
* If the surface is corroded, or if the blades are dam-
aged, replace the impell er.
A. Impel ler B. Blades
Water Pump Shaft Removal
Impel ler
Right Engine Cover (see Right Engine Cover in
the Engine Right Side chapter)
- Pull out the water pump shaft toward inside of the
right engine cover.
oBe sure to pull out the shaft toward the inside of
the cover to prevent the oil seal lips from peeling.
A. Water Pump Shaft
Water Pump Shaft Installation Notes
- Instal l ation is the reverse of removal.
- To prevent the oil seal lips from peeling, apply a
molybdenum disulfide grease to the water pump
shaft and insert it into the oil seal from the inside
of the right engi ne cover.
Water Pump Shaft Installation
KX125, 250:
1
1. Oil Seal
3. Marked Side
2. Water Pump Shaft 4. Right Engine Cover
KX500,
1
2
3
1. Oil Seal 3. Marked Side
2. Water Pump Shaft 4. Right Engine Cover
oBe sure to apply a molybednum disulfide grease
to the water pump s haft when installing . If it is in-
stalled dry. the seals may wear excessively.
COOLING SYSTEM 3-11
Oil Seal Removal
- Remove the fol lowi ng parts.
Impeller
Right Engine Cover (see Right Engine Cover in the
Engine Right Side chapter)
Water Pump Shaft
-Insert a bar into the water pump shaft hole from
the outside of the right engine cover, and remove
the ball bearing by tappi ng evenly around the bear-
ing inner race.
- Insert a bar into the water pump shaft hole from
the inside of the right engine cover, and remove
the oil seal by tapping evenly around the seal
lips.
Oil Seal Installation
olf the oil seal or ball bearing is removed. replace
all of them with new ones at the same time.
- Apply ple nty of high temperature grease to the oil
seal lips.
- Press the oil seal into the hole from the outside of
the right engine cover wit h a bearing driver set
special tool) so that the marked side faces toward
the inside of the cover.
cUse a bearing driver larger in diameter than the
oil seel, and press the oil seal into the hole until
the edge of the oil seal is flush with the step for
the ball bearing.
Oil Seal Installation
1. Oil Seal
2. Apply High Temperature Crease
3. Bearing Driver Set: 5700' -11 29
4. Step
3-12 COOLING SYSTEM
Press the ball bearing into the hole with a bearing
driver set (special tool: 57001-1129) untif the bear-
ing is bottomed against the step.
Radiator
Radiator Removal
- Remove the radiator cover(s).
- Drain the coolant (see Coolant Draining).
- loosen the hose clamps, and pull off the cooling and
breather hoses.
- Remove the mounting bolts, and take out the radiator
and radiator cover.
Radiator Installation
- Install ation is the reverse of removal (see Coolant
Fi ll ing).
Radiator Inspection
Check the radiator core.
'*' If there are obstructions to air flow, remove them.
* If the corrugated fins are deformed, carefully straight-
en them with the thin blade of a screwdriver.
000 not tear the radiator tubes whAe straighten-
ing the fins.
A. Thin Scre'o'ldriver
* If the air passages of the radiator core are blocked
more than 20% by unremovable obstructions or irrep-
arably deformed fins, replace the radiator with a
new one.
oWhen c ~ n l n g the radiator with compressed air,
be cereful of the following to avoid damage to
the fins.
a Keep t he air nozzle over 0.5 m 120 in.1 away
from the radiator.
a Blow air perpendicularly to the radiator core.
a Navar blow air at an angle against the fins but
straight through them in the direction of natural
air flow.
a Na var s hake the air nozzle at a right angle against
the fins . be s ure to move it at a level with the
fins .
Radiator Cleaning
(obliquity)
( perpendicular)
more t an
O,S m
Radiator Cap Inspection
OK
- Check the condition of the va lve spring, and the top
and bottom va lve seals of the radiator cap.
* If anyone of them shows visible damage, replace
the cap.
1. Valve Spring 3. Bottom Valve Seal
2. Top Valve Seal
.Wet the top and bottom valve seals with water or
coolant to prevent pressure leaks.
- Install the cap on a cooling system pressure tester
- Watching the pressure gauge, pump the tester to
build up the test pressure. The cap must open at the
specified relief pressure (the gauge hand flicks down).
COOLING SYSTEM 3- 13
1. Pressure Tester 2. Radiator Cap
Radiator Cap Relief Pressure:
95- 125kPa 10.95- 1.25 kg/cm
2
, 14-18 psi)
OAlso. the cap must hold t he relief 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.
Filler Neck Inspection
-Check the radiator filler neck fOf signs of damage.
- Check the condition of the top and bottom sealing
seats in the filler neck. They must be smooth and
clean for the radiator cap to function properly.
A. Top Seali ng Seat B. Bottom Sealing Seat
Cooling Hoses, Breather Hose Inspection
- In accordance with the Periodic Maintenance Chart.
visuall y inspect the hoses for signs of deterioration.
Squeeze the hose. A hose should not be hard and
brittle, nor should it be soft or swollen.
- Replace any damaged hose.
3-14 COOLING SYSTEM
Cooling Hoses, Breather Hose
Installation Notes
- Install the cooling noses or breather hose being
careful to follow the preformed bends (see Exploded
View, Hose Routing in the Cenerallnformation c h ~
ter1 Avoid sharp bending. kinking,. flattening. or
twisting.
- Tighten the hose clamps securely.
A. Cooling Hoses B. Breather Hose
A. Breather Hose
ENGINE TOP END 4-1
Engine Top End
Table of Content s
Exploded View ......................................... _ ......... .............. ....... .
Specifications ..................... _ . . ..... . ... . .. .. .... .. ... .... . ................
Special Tools . .. .... ......... . ....... . .. . ... . ........ . .... .. ..... .. . .. .... . .. . . .. .....
Cylinder Head ...... . ....... , ........................... _._ ....... _,_ ......... .. ..... ..
Cylinder Compression Measurement .... .... " ....................... ,' ..
Cylinder Head Removal .... . ............... . .. _ ..........................
Cylinder Head Installation Notes .. .. . .. . . _._ .. .... . ............... _. _ . .. . .
Cylinder Head Warp Inspection .... ..... . . . .. ... .. . . ... ... .. ..... . ... . .. .
Exhaust Valve (KIPS) ., ....................... , ................................... .
Exhaust Valve Removal .. . ............. . .. ... ..... ...... . . ... . ..... .. .. .. . .
Exhaust Valve Installation Notes ......................... . ............. .
Cylinder, Piston ........................... . ...... . .......... . .. .... . ......... . ... . .. .
Cylinder Removal ..... ............. ... ..................... . .. ............... .
Cylinder Installation Notes .. , ..... . ................... , ................... .
Piston Removal ..................... .... .. .... . .. .. .. .... .. ... ......... ... .... .
Piston Installation Notes .......... .. ............ , .. , ................ , ..... .
Cylinder Wear Inspection . . ......... . ........ ............................... .
Piston Diameter Measurement .... ... .. ... .... ... ..... . .. ........... . .... ..
Piston/Cylinder Clearance ................ . .......... . ...................... ..
Piston Ring, Piston Ring Groove Inspection ......................... ..
Piston Ring End Gap Inspection ......................................... ..
Piston, Piston Pin, Connecting Rod Wear Inspection ............ ..
Muffler (Expansion Chamber, Silencer)
4-2
4-5
4-8
4-9
4-9
4-9
4-9
4- 10
4-10
4- 10
4- 13
4- 16
4- 16
4-17
4- 17
4- 17
4- 18
4-19
4- 19
4-20
4-20
4-20
4-21
Expansion Chamber Removal .................... . ....... ...... ............. 4-21
Expansion Chamber Installation Notes ........ ............ ... ...... ..... 4-21
Silencer Wool Change ...... ................... ..... .. .......... ...... ........ 4-21
D
4-2 ENGINE TOP END
Exploded View
T1 : 25 N-m 12.5 kg-m. 18.0 ft -Ib)
T2: 26N-m 12.6 kg-m. 19.0 ft-Ibl
T3: 6.9 N-m (0.7 kg-m. 81 In-Ibl
T4: 9.8 N-m 11 .0 kg-m. 87 In-fbI
T5: 25 N-m 12.5 kg-m. 18.0 ft -Ibl
T6: 8 .9 N-m 10.7 kg-m. 61 In-fbI
T7: 8 .3 N-m (0.86 kg-m, 74 in-Ib)
T2
KX250:
18.0 ft-Ibl
25 N-m 12.5 kg-m. 19.0 ft-Ibl
T1 : 25 N-m (2.6 kg-m. 61 In-Ib)
T2: 6 9 N-m 10. 7 kg-m, 87 in-Ib)
T3: 9' S N-m (1 .0 k
g
-m' 26 ft-Ibl
T4: 34 N-m 13.5 k : ~ : 11 fHb)
T5. 15 N-m 11 .5 kg 87 in-Ibl
T6: 8 N-m '1 .0 kg-m. 87 in-Ib)
T7: 9 . m 11.0 kg-m.
T8: 9.8 N
" .

ENGINE TOP END 4 3
4-4 ENGINE TOP END
KX500:
n :
T2:
T3:
T4:
T5:
T6:
T7:
26 N-m (2 6 k
25 N-m (2'S k
g
-
m
18 ft-Ib)
6.9 N-m (0 7 :-m. 19 ft -Ib)
34 N-m (3 6 k g-m, 61 in-Ibl
20 N-m (2' O k g-m. 25 ft -Ib)
9.8 N-m 11 0 :-m. 14.5 fHb)
9.8 N-m (1 ' 0 k g-m. 87 in-Ib)
. g-m, 87 In-Ib)
ENGINE TOP END 4-5
Specifications
KX125:
Cylinder Head:
Cylinder compression (usable range) ---
770 - 1200 kPa
(7.7 - 12 kg/cm
2
109-171 psil
Cylinder head warp ---
0.03 mm
Cylinder. Piston:
Cylinder inside diameter 56.015-56.030 mm 56. 10 mm
Piston diameter 55. 940- 55.955 mm 55.79 mm
Piston/ cylinder clearance 0 .071 -0.091 mm ---
Piston ring/groove clearance 0 .04- 0 .08 mm 0. 18 mm
Piston ring groove width 0 .83- 0 .85 mm 0 . 93 mm
Piston ring thickness 0.77 - 0 . 79 mm O. 7mm
Piston ring end gap 0 . 15-0.35 mm O.7mm
Piston pin diameter 15. 995- 1 6.000 mm 15. 96 mm
Piston pin hole diameter 16.000- 1 6.006 mm 16.07 mm
Small end inside diameter 21.003- 21 .014 mm 21 .05 mm
4-6 ENGINE TOP ENO
KX250:
Item
Cylinder Head:
Cylinder compression
Cylinder head warp
Cylinder. Piston:
Cylinder inside diameter:
Piston diameter:
Piston/cylinder clearance
Piston ring/groove clearance
Pi ston ring groove width
Piston ring thickness
Piston ring end gap
Piston Pin diameter
Piston pin hole diameter
Small End inside diameter
Standard Service Limit
(usable range)
---
840-1300 kPa
18.4-13 kg/em'. 119 - 185 psil
- -- 0.03 mm
67.400-67.415 mm 67.48 mm
67. 341-67.356 mm 67.23 mm
0 .054-0.074 mm
---
0.04- 0.08 mm 0. 18 mm
1.03-1.05 mm 1. 10 mm
0.97 -0.99 mm O. 9mm
0 . 15-0.35 mm O. 7mm
17. 995-18.000 mm 17.96 mm
18.000-18.006 mm 18.07 mm
22.003-22.014 mm 22.05 mm
ENGINE TOP ENO 4-7
KX500:
Cylinder Head:
Cylinder compression (usable range)
---
735- 1150 kPa
17.35- 11.5 kg/em', 105- 1 64 psi!
Cylinder head warp --- 0.03 mm
Cylinder. Piston:
Cylinder inside diameter 86.020-86.035 mm 86.10 mm
Piston diameter 85.910-85.925 mm 85.80 mm
Piston/cylinder clearance 0.105-0. 125 mm
---
Piston ring/groove clearance 0.05-0.09mm 0.19 mm
Piston ring groove width 1.24- 1 .26 mm , .34 mm
Piston ring thickness 1. 17-1.19mm '.10 mm
Piston ring end gap 0 .2-0.4 mrn 0.70 mm
Piston pin diameter 18.995- 1 9.000 mm 18.96 mm
Piston pin hole diameter 19.000- 1 9.006 mm 19.07 mm
Small end inside diameter 24.002-24.013 mm 24.05 mm
4-8 ENGINE TOP END
.. ..... ........ .. ......... .... ................. ....... .... .. .
Special Tool
Compression Gauge: 57001221
Adapter: 57001 1159
Piston Pin Puller Assembly: 57001 -910
Piston Ring Plie,s: 6700' -115
o
o
o
.. .......................................... .... ..............
Cylinder Head
Cylinder Compression Measurement
- Start the engine
- Thoroughly warm up the engine so that the engine oil
between the piston and cylinder wall wi ll help seal
compression as it does during normal running.
- Stop the engine.
- Remove the spark plug. and screw a compression
gauge (special tool) firmly into the spark plug hole.
- With the throttle fully open. tum the engine over
sharply with the kickstarter several times until the
compression gauge stops rising; the compression is
the highest reading obtainable.
Cylinder Compresakln (UsalM Rangel :
KX125 : 770- 1200kPa 17.7 - 12 kg/em!.
'09- 17' psil
KX250 : 840-13OOkPa (8.4 - 13 kg/em!.
119-'85 psil
KX500 : 735- 11SOkPa 17.35-11 .5 kglcm'.
'05- '64 poil
A. Compression Cauge: 57001221
B. Adapter. 57001-11 59
* If cylinder compression is higher than the usable
range. check the following:
1. Carbon buil d-up on the piston head and cylinder
head - clean off any carbon on the piston head
and cyli nder head.
2. Cylinder head gasket. cylinder base gasket - use
only the proper gaskets for the cyli nder head and
base. The use of gaskets of the incorrect thickness
will c hange the compression.
* If cylinder compression is lower than the usable
range. check the following:
1. Piston/cylinder clearance. piston seizure.
2. Gas leakage a round the cylinder head - replace
the damaged gasket and check the cyli nder head
for warping.
3. Piston ring. piston ring groove.
ENGINE TOP ENO 4-9
Cylinder Head Removal
- Drain the coolant (see Coolant Change in the
Cooling System chapter).
- Remove the following parts:
Seat
Fuel Tank
Radiator Cover
Muffler
Spark Plug
Water Hose lower End
A. Spark Plug B. Water Hose
- Remove the engine mounti ng brackets on the cyli nder
head.
A. Engine Mounting Brackets
- Remove the cylinder head bolts or nuts, and take
off the cylinder head and gasket.
Cylinder Head Installation Notes
-Install ation is t he reverse of removal.
- Replace the head gasket with a new one.
- Scrape out any carbon and clean the head with
a high flash-point solvenl
-Check for a crust of minerals and rust in the head
water jacket. and remove them if necessary.
- Tighten the engine mounting bracket bolts on the
cyli nder head to the specified torque.
rtghtening Torque
25 N-m 12.6 kg.m. 19.0 fHb)
4-10 ENGINE TOP END
- Tighten the cylinder head bolts or nuts to the spe-
cified torque.
Tightening Torque:
25 N-m (2.5 kgm. 18 ft - Ibl
- Tighten the spark plug to the specified torque.
Tight ening Torque:
27 N-m 12_8 kg-m_ 20 ft - Ibl
Cylinder Head Warp Inspection
Lay a straightedge across t he lower surface of t he
head at several different poi nts, and measure warp
by inserting a thickness gauge between the straight-
edge and the head.
* If warp exceeds the service limit, repair the mati ng
surface. Replace the cylinder head if the mat ing
surface is badly damaged.
A. Straightedge
Cytinder Head Warp
SefVice Umft:
B. Thickness Gauge
0.03 mm
Exhaust Valve (KIPS)
Exhaust Valve Removal
- Remove the cylinder head (see Cylinder Head Re-
moval).
- Remove the right cover at the cylinder.
- Remove the shaft lever mounting bolt or nut, and
take off the shaft lever.
oExhaust valve operating shaft lever nut for the
KX126 has left-hand threads.
- Remove the exhaust valve operating rod retaining
screw.
KX125:
A. Shaft l ever C. Retaining Screw
B. Shaft lever Mounting Nut
KX250
A. Shaft lever
B. Shaft lever Mounting Nut
C. Retaining Screw
ENGINE TOP ENO 4-"
KX500: - Remove the idle gear.
- Lift up the right and left exhaust valves until the
gear surfaces a re flush with cylinder surface.
p
A. Shaft Lever C. Retaining Screw .
B. Shaft lever Mounting Nut 0
KX'25:
- Remove the main exhaust valve cover bolts,
and remove the cover and gasket.
A. Cover B. Gasket
- Pull out the operating rod as far as it goes.
Pull out the main exhaust valve unti l groove on
the main exhaust valve holder coincide with
cyli nder surface.
A. Groove
3
1. Idle Gear
2. Flush
3. Main Exhaust Valve
- Remove the valve operating rod retaining screw.
- Pull out the exhaust valve operating rod.
- Remove the right and left exhaust valves.
- Unbolt the resonator.
A. Resonator
4-12 ENGINE TOP END
- Remove the cylinder. and remove the main exhaust
valve.
A. Main Exhaust Valve
KX250:
- Up side down the cylinder.
' Remove the plug and gasket.
A. Plug B. Gasket
' Push in the operati ng rod as far as it will go. This
cause to align the punch marks on the exhaust
va lve with the notch on the operating rod (see
Exhaust Valve Installation Notes).
- Remove the idle gear.
' uft up the exhaust va lves, and remove the O-rings
and valve guides.
-
A. Exhaust Valves
B. O-Rings
C. Valve Guides
D. Valve Operati ng Rod
E. Idle Gear
-Remove the va lve operating rod retaining screw.
t Uft up the exhaust va lves, and pullout the val ve
operati ng rod.
- Take out the exhaust valves.
' Remove the main exhaust valve cover bolts, and
remove the cover and gasket.
A. Cover
B. Casket
- Remove the mounting bolts, and remove the main
exhaust valve.
A. Bolts
B. Main Exhaust Val ve
KX500:
- Up si de down the cylinder.
- Remove the plug and gasket.
- Remove the pin on the cylinder.
- Remove the val ve guide from the exhaust valve.
A. Exhaust Valve C. Pin
B. Valve Gui de
- Unbolt the left plug.
- Pull up the exhaust valves, and then pull out the
valve operating rod to the right side.
A. Valve Operating Rod
8. Exhaust Valves
- Take out the exhaust valves.
Exhaust Valve Installation Notes
- Installation is the reverse of removal .
- Scrape out any carbon and clean the valves with a
high flash-point solvent
- Check the exhaust valves and val ve operating rod
for signs of damage. If necessary. replace them with
new ones
- Check the gasket and oil seal on the rod seal plug
for signs of damage. If necessary, replace them with
new ones,
- Check the O-rings on the valve guides for signs of
damage. If necessary, replace them with new ones.
ENGINE TOP END 4-1 3
- For KX125, 250 model ; be careful not to mi x up
the ri ght and left exhaust val ves. The right valve
has an identifing groove.
A. Groove
- Apply a 2 stroke engine oil to the f oll owing:
Exhaust Valve Upper and lower lournals
Exhaust Valve Pinions
Valve Guides (inside)
Valve Operating Rod Journal s
Valve Operating Rod Rack
- Apply a high temperature grease to the oil seal lip
on the operating rod.
- Adjust the exhaust val ve position in accordance
with the following procedure.
oFor KX125 model; after installing the rod retaining
screw in the cylinder with the val ve operating rod,
pull the rod to the right side as far as it will go.
OEngage the left val ve pi nion with the rod rack so
t hat the punch mark on t he pinion is positioned
toward the front of the engine. The punch mark
on the valve pinion should align with the groove on
the rod.
olnstall t he idle gear so that the punch mark on
the idle gear pinion ali gns with right valve pinion
punch mark.
4-14 ENG.lNE TOP END
KX1 25 Model Exhaust Valve Operating Rod Install ation
3
@) 00
I D ~ D I D )
1. Exhaust Valves
2. Idle Gear
3. Punch Ma rk
4. Guide
5. Mai n Exhaust Val ve
aFor KX2S0 model ; tighten the main exhaust valve
bracket mounting bolts securely. Check that there
is no gap between the bracket and cyli nder.
00
1. No Cap
2. Bracket
ENGINE TOP END 4- 15
oEngage the valve pinions with the rod rack so that
the paint marks on the pinions are positioned to-
ward the front af the engine. The paint marks on
the valve pinions should align with the groove on
the rod.
NOTE
aThe marked tooth is identified by Its s hape also.
1. Marked tooth
2. Paint Mark
KX250 Model Exhaust Valve Operating Rod Inst allation
1. Idle Gear
2. Right and l eft Exhaust Valve
3. Paint Mark
4. Groove
OCheck the gasket on the left plug for signs of
damage. If necessary, replace it with new one.
olnst all the left plug on the cylinder, and tighten
it to the specified torque.
Tightening Torque
15 N-m 11.5 kg-m, 11 ft -Ibl
aFar KX500 model ; check the gasket on the left plug
for' signs of damage. If necessary, replace its with
new one.
olnstall the left plug on the cylinder, and tighten it
to the specified torque.
4- 16 ENGINE TOP END
Tightening Torque
20 N-m 12.0 kg-m. 14.5 ft-Ibl
A. Valve Operat ing Rod D. Exhaust Valves
B. Oil Seal E. Val ve Guides
C. O-Ring
OPut the exhaust valves into the holes in the cyl-
inder.
o AppJya 2-stroke engine oi l to the teeth of the valve
operating rod.
oPull up the exhaust valves, insert the valve oper-
ating rod, and push down the valves.
A. Exhaust Valves ' B. Valve Operating Rod
oPuli up t he exhaust valves and ali gn each exhaust
valve punch mark with the groove on the valve
operati ng rod.
A. Punch Mark 8. Groove
Cylinder, Piston
Cylinder Removal
- Drain the coolant
- Remove the f ollowi ng part s:
Cylinder Head
Clutch Cable Lower End
- Loosen the damps. and pult the carburetor out of
the holder and the air cleaner duct.
- Remove the carburetor holder mount ing bolts, and
pull the holder out to the rear.
- Remove the ri ght cover at the cylinder.
- Remove the shaft lever mounting bolt or nut, and
take off the shaft lever.
A. Shaft l ever
oExhaust valve operating shaft lever nut for the
KX125 has left-hand threads.
- Remove the cyl inder nuts.
- lift off the cylinder, and remove the cylinder base
gasket. If necessary, tap lightly around the base of
the cylinder with a plastic mallet. taking care not
to damage the cylinder.
A. Plastic Mall et
- Remove the exhaust valves from the cyli nder.
Cylinder Installation Notes
- Installation is (he reverse of removaL
- Scrape any carbon out of the exhaust port.
- Check for a crust of minerals and rust in the cylinder
water jacket, and remove them if necessary.
- Replace the cylinder base gasket with a new one.
- Apply engine oil to the piston surface, piston rings
and cylinder bore.
- Check to see that the pin in each piston ring groove
is between the ends of the piston ring. and fit the
base of the cylinder over each ring. pressing in on
opposite sides of the ring as necessary. Be certain that
the rings do not slip out of position.
- Tighten the cylinder nuts to the specified torque.
Tightening Torque:
KX125, 25 N-m 12.5 kg-m. 18 ft-Ibl
KX250. 500, 34 N-m 13.5 kg-m. 25 ft-Ibl
-Tighten the shaft lever bolt or nut to the specified
torque.
TIghtening Torque
KX125 INutl : 8.3 N-m (0.85 kg-m, 74 1n-lbl
KX250 (Nut): 9.8 N-m (1 .0 kg-m, 87 in-Ibl
KX600 (Bolt): 9.8 N-m (1 .0 kg-m, 87 in-lbl
- Refer to Carburetor Installation Notes in the Fuel
System chapter for carburetor installation.
Piston Removal
- Remove the cyl inder.
- Stuff a clean cloth into the crankcase opening around
the connecting rod so that no parts will fall into the
crankcase.
-Remove one of the piston pin snap rings with needle
nose pliers.
- Remove the piston by pushing the piston pin out the
side from which the snap ring was removed. Use a
piston pin puller assembly (special tool), if the pin
is tight.
A. Piston Pin Puller Assembly: 57001-910
ENGINE TOP END 4-17
- Remove the top and second rings with piston ring
pliers (special tool). If the special tool is not available,
carefully spread the ring opening with your thumbs
and then push up on the opposite side of the ring
to remove it.
A. Piston Ring Pliers: 57001-115
Piston Installation Notes
-I nstallation is the reverse of removal .
Stuff a clean doth into the crankcase opening
around the connecti ng rod so that no parts will fall
into the crankcase.
- Scrape a ny carbon off of the piston, then lightlv
polish the piston with fine emery doth.
- Clean carbon and dirt out of the piston ring grooves
using a suitable tool.
oCarbon particles can be very abrasive to piston
rings. Don' t allow such particles to faU onto the
cylinder wa.s.
4-18 ENGINE TOP END
- When installing the piston rings on the piston, note
the following;
olf installing the piston rings by hand. first fit one
end of the piston ring against the pin in the ring
groove, spread the ring opening with the other hand
and then slip the ring into the groove.
aFar the KX250 model; both the top and the second
rings have a mark on their upper surface
Olnstall the rings so that the pin in each piston ring
groove is between the ends of the piston ring.
Piston Ring Position
<D
1. Pin
- Apply 2stroke engi ne oil to the connecting rod nee-
dle bearing and the piston pin.
-I nstall the piston and piston pin. The arrow on the
top of the piston must point toward the fronl
- When installing a piston pin snap ring, compress it
only enough to install it and no more.
0 00 not reuae anap rings. as removal weakens
and deforms them. They could fall out and score
the cylinder wall .
- Fit a new piston pin snap ring into the side of t he
piston so that the ring opening does not coincide
with the notch in the edge of the piston pin hole.
A. Arrow C. Ring Opening
B. Snap Ring D. Notch
Cylinder Wear Inspection
NOTE
OMeasure the cylinder inside diameter when the
cylinder is cold (room or ambient temperature).
-Inspect the inside of the cylinder for scratches and
abnonnal wear.
* If the cylinder is damaged or badly worn, replaceit
with a new- one.
- Si nce there is a difference in cylinder wear in
different directions, take a and a front-
to-back measurement shown in the figure.
* 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-
FUSION cylinder cannot be bored or honed.
Cylinder Inalde Diameter Measurement
@:KX125 - 18 mm
KX2S0,SOO - 30 mm
KX125:
Standard:
SelVice Umit:
KX250:
Standanl:
56. 015 - 56.030mm, and less
than O.01mm difference between
any two measurements.
66. 10mm. or more than O.05mm
difference between any two
measurements.
67. 400- 67.415mm. and leas
than O.Olmm difference between
any two measurements.
Service Umit: 67.48mm. Of more than 0.06mm
difference between any two meaa-
ments.
KX500:
Standard: 86.020- 86.035mm. and leIS
than O.Olmm difference between
any two measurements
Service limit.: 86.1 Omm. Of more than 0.05mm
difference between any two meas
ments
Piston Diameter Measurement
Measure the outside diameter of the piston 18 mm
(KX12S),20.S mm (KX250) or 265 mm (KXSOO) up from
the bottom of the piston at a right angle to the
direction of the piston pin.
* If the measurement is under the service limit. re-
place the piston.
Piston Diameter
KX125:
Standard:
SeMca l J m ~
KX250:
Standard:
ServIce Umtt:
KX500:
Standard:
Service Urnit:
55.940- 55.955 mm
55.79 mm
67.341-67.356 mm
67.23 mm
85.910-85.925 mm
85.80 mm
ENGINE TOP END 4- 19
@:KX125 - 18 mm
KX2S0 - 20.5 mm
KXSOO - 26.5 mm
Piston/Cylinder Clearance
The pistonta-cylinder clearance is measured
whenever a piston or cylinder is replaced with a new
one. The standard pistorHo-cylinder clearance must
be adhered to whenever the cylinder is replaced.
If onl y a piston is replaced. 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 pistOfl and cylinder diameter
measurements and then computing the difference
betw'een the two values. Measure the piston diameter
as just described. and measure the cylinder diameter
at the very bottom of the cylinder.
Piston/Cyinder Clearance
KX125:
KX250:
KX500:
0.071 - 0 .091 mm
0.054- 0.074 mm
0.105- 0 .125 mm
4-20 ENGINE TOP END
Piston Ring. Piston Ring Groove Inspection
Visuallv inspect the piston rings and the piston
ring grooves.
* If the rings are worn unevenly or damaged, they
must be replaced.
* If the piston ring grooves are worn unevenly or
damaged, the piston must be replaced and fitted with
new rings.
Check fOl' uneven groove wear by inspecting the ring
seating.
* The rings should fit perfectly paralJel to the groove
surfaces. If not, the piston must be replaced.
With the piston ring in its groove, make several
measurements with a thickness gauge to determine
piston rins/groove clearance.
* If the clearance exceeds the service limit, measure
the thickness of the piston ring.
*If the ring has worn down to less than the service
limit. replace the ring; if the groove width exceeds
the service li mit, replace the piston.
PIston Ring/Groove Clearance
Standard: KX125. 260: 0.04-0.08 mm
KX500: 0.05- 0.09 nvn
_ UnIt:KXI25.250: 0.18 nvn
KX500: 0.19 nvn
PIoton RIng llW:kness
Standard: KX125: 0.77- 0.79 rnm
KX250: 0.97 - 0.99 nvn
10(500: 1.17-1. 19 mm
_ UnIt: KX125: 0.7 nvn
KX250: 0.9 mm
KX500: 1.10 nvn
PIston Rilg Groove Width
Standard: KX125: 0.83- 0.86 rnm
KX250: 1.03- 1.05 mm
KX600: 1.24-1.26 mm
_ UnIt: KX126: 0.93 mm
KX260: 1.10 nvn
KX500: 1.34 mm
A. Thickness Gauge
Piston Ring End Gap Inspection
Place the piston ring inside the cylinder, using the
pistOf'l to locate the ring squarely in place.
Set it dose to the bottom of the cylinder. where cyl-
inder wear is low.
Measure the gap between the ends of the ring with
a thickness gauge.
* If the gap is wider than the service limit, the ring is
overwom and must be replaced.
Piston Ring End Gap
Standard: KXI25.250:
KX500:
Service Umit: 0.70 mm
RIng End Gap Me8SU1HTl8flt
0.15- 0.35 mm
0.2- 0.4 mm
1
00
1. Piston Ring 3. Thickness Gauge
2. Cylinder Block
Piston, Piston Pin,
Connecting Rod Wear Inspection
Visually inspect the snap ring still fitted in place.
* If the ring shows weakness or defonnation, replace
the ring. Also if the pin hole groove shows exces-
sive wear. replace the piston.
Measure the diameter of the piston pin with a micro-
meter.
* If the pistOf'l pin diameter 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.
Pi ston Pin Diameter
KX1 2S,
Standard:
Service limit :
KX2S0,
Standard:
Service Limit :
KXSOO,
Standard:
Service Limit :
15.995- 16.000 mm
15.96 mm
17.995- 18.000 mm
18.96 mm
18.995- 19.000 mm
18.96 mm
Pi ston Pin Hole Diameter
KX12S,
Standard:
Service Limit :
KX2S0,
Standard:
Service Limit :
KXSOO,
Standard:
Service Limit :
16.000- 16.006 mm
16.07 mm
18.000- 18.006 mm
18.07 mm
19.000- 1 9.006 mm
19.07 mm
Small End Inside Diameter
KX12S,
Standard:
Service Limit:
KX2S0,
Standard:
Service Limit:
KX500,
Standard:
ServicQ limit:
A. Snap Ring
21 .003-21.014 mm
21 .05 mm
22.003- 22.014 mm
22.05 mm
24.002-24.013 mm
24.05 mm
B. Piston Pin
ENGINE TOP END 4-21
Muffler (Expansion Chamber, Silencer)
Expans;on Chamber Removal
- Remove the right or left side covers.
- Remove the silencer.
- Remove the exhaust pipe holdi ng springs.
- Remove the muffler damper mounting nut, and
pull off the expansion chamber to the frontward.
A. Muffler Damper Mounting Nut
B. Exhaust Pipe Holding Springs
Expans;on Chamber Installat;on Notes
- Scrape any carbon out of the expansion chamber.
- Check the exhaust Orings for signs of damage. If
necessary, replace them with new ones.
Silencer Wool Change
Replace the silencer wool if exhaust noise becomes
too loud or engine performance drops.
- Remove the inner pipe mounting boits, and pull the
inner pipe out toward the rear.
- Pull off the old si lencer wool, and wrap new si lencer
wool around the inner pipe.
- Install inner pipe into the silencer.
Silencer
A. Mounting Bol ts B. Inner Pipe
ENGINE RIGHT SIDE 5-'
Engine Right Side
Table of Contents
Expl oded View .......... .. .. .. ................... ,..... .. . .. ........ . .... .. ...... 5-2
Specifications ........... " ........... , .. ... . ........... , ........................ ,. ,... 5- 5
Special Tool s .. ... .... . ............. .. .. . ...... .. .. ............. .. ........ ... .. .. . . .. . .. 5-5
Right Engine Cover ................... . ... .. .................... .. .... . ....... . ,...... 5-6
Right Engine Cover Removal ..................... ............. .. ........... 5-6
Right Engine Cover Installation Notes .""."... . .................... . .. 5-6
Right Engine Cover Di sassembly ... .... .. . ... . .... ... .. . .. .. ..... ......... 5-7
Exhaust Advancer Assembly Disassembly/Assembly Notes .. "". 5-9
Right Engine Cover Assembly Notes .................. ... . ....... . ..... . 5-9
Clutch ....... . .......... ... . ......... . .... .. .. .. .... ...... .. ... .. . . . .... .. .............. 5- 10
Clutch Adjustment .................... ... ........... .............. .. ......... 5- 10
Clutch Removal /Disassembly ........... ......... . . ...... ........ . ..... 5- 1 0
Clutch Installation Notes .......... .................. ...... .. . . .... ..... . .. . 5-12
Friction Plate Wear , Damage Inspection . ... . .... .... . .... .............. 5- 12
Friction and Steel Plate Warp Inspect ion 5-13
Clutch Spring Free Length Measurement . .. .......... ... ......... ..... 5- 13
Clutch Plate/Clutch Housing Clearance ..... . ......... ... ............... 5-13
Clutch Hub Spline Inspection ...... . . ...... . .. . .......... ................... 5-13
External Shift Mechanism ..... ,., ............. ... , .. , .......... ,............. .. . ... 5-14
External Shift Mechanism Removal ... .. . ...... ... .. ..................... 5- 1 4
External Shift Mechanism Installation Notes .. .. ...... ... .... .. .... ... 5-14
External Shift Mechanism Inspection ... .......... ... .. . ........ ......... 5- 14
Primary Gear .. . .......... " ........ "" ... " ... ............ " ....... ... ,................ 5- 15
Primary Gear Removal ...................... .............. ..... ... . .... ....... 5- 15
Primary Gear Installation Notes ....... .... ... .. .... ......... ....... ........ 5-15
Kickstarter .... ...................... .......... . . . .... . .. .... .. . .. .. ... .... ..... .......... 5- 16
Kickstarter Assembly Removal .... . ........................................ 5-16
Kickstarter Assembly Installation Notes ................. .. ............. 5-17
Kickstarter Assembly Disassembly/ Assembly Notes ..... " ...... .. 5-17
Kickstarter Idle Gear Removal Notes .... . ...... ......... ................ 5- 17
Kickstarter Idle Gear Installation Notes .. .. ....... .. .... .. .............. 5- 17
ENGINE RIGHT SIDE
... "" .
Exploded ....... ....... ... .............. .
. .. .. ... ... .. w ... .
KX
....
125: .. .. .. .. .. ... .. . .. ... .
..... .. ..........
o
?
o '''-" ..
T3: 9.3 N' m (0.95 r
m
81 inlb)
T4: 78 N'm (8 kg-m g-m. 82 in-Ib)
T5: N'm 10.85 k 58 ft lbl
T6: .9 Nm (0.4 k g-m. 74 in-Ib)
T1: 2.0 N-m 10 .2 k g-m, 35 in-lbJ
TS: 59 N-m 16.0 k g-m, 17 in-Ibl
T9: 9.8 N-m (1 ,0 :-m. 43 ftlb)
no- 9.8 Nm 11 .0 k g-m, 87 inlb)
n1 : 22 N-m 12.2 k 87 in-Ibl
. 9.8 N-m (10 kg m. 16.0 ftlb)
. g-m. 87 ft -Ib)
KX250
T1, 9.3 Nm 10.95 kg-m. 82 Inlbl
T2: 9 .8 N-m 11 .0 kg-m, 87 In-Ib)
T3: 98 N-m (10 kg-m, 60 ft-Ib)
T4: 9.8 N-m (1.0 kg-m. 87 in-Ibl
T5: 3.9 N-m (0.4 kg-m. 35 in-Ibl
T6: 2.0 N-m (0 .2 kg-m. 17 in-Ibl
T7: 9.8 N-m 11 .0 kg-m. 87 in-Ibl
T8: 9.8 N-m (1 .0 kg-m. 81 in-Ibl
T9: 22 N-m (2.2 kg-m. 16 ft -Ibl
no: 9.8 N-m 11 .0 kg-m. 87 In-Ih)
ENGINE RIGHT SIDE 5-3
54 ENGINE RIGHT SIDE
KX500:
~ 8
~
T1: 9.8 N-m 11 .0 kg-m. 87 In-Ibl
T2: 3.9 N-m 10.4 kg-m. 36 In-Ibl
T3: 2.0 N-m (0.2 kg-m. 17 In-Ibl
T4: 9.8 N-m 11 .0 kg-m. 87 in-Ib)
T5: 9.3 N-m 10.96 kg-m, 82 In-Ibl
T6: 98 N-m (10 kg-m. 72 ft-Ibl
T7: 9.8 N-m 11 .0 kg-m. 87 In-Ib'
T8: 20 N m 12.0 kg m. 14.6 ftlbl
19: 9.8 Nm 11 .0 kgm. 87 Inlbl
\
T7
l : Apply a non-permanent locking agent to the
threads.
M : Apply molybdenum diwlficl e grease.
G : Apply high temperature grelH.
o : Apply tflnllTli u ion oil.
. .......... ............... . .... . ............... . .. ..
Specifications
Item
Clutch:
Clutch lever free play
Clutch Spring free length KX125
KX250
KX500
Friction plate thickness KX125
KX250. 500
Friction plate/clutch housing clear-
ance
Friction and steel plate warp
..... .. .... . .. . , ........... , ...... . .. ' ......... . .. .
Special Tools
Circlip Pliers: 57001-144
Kick Shaft Oil Seal Guide: 57001 -263
Shift Shaft 011 Seal Guida: 57001264
2 - 3 mm - --
39.4 mm 37,9 mm
33.3 mm 31.6 mm
32,6 mm 31.1 mm
2,92 - 3,08 mm 2.7 mm
2,92 - 3,08 mm 2.8 mm
0,35 - 0,60 mm 0 .9 mm
not more than 0 . 15 mm 0.3 mm
__ : &7001-1248

Rotor Holder Adapter "A": 57001-"08
Clutch Holder: 57001 -1243
NOTE
oThe flywheel holder (PI N 5700J - J 313' can be used
instead of the rotor holder (PI N 57001-1248) .
56 ENGINE RIGHT SIDE
Right Engine Cover
Right Engine Cover Removal
- Drain the transmission oil (see Transmission Oi l
Change in the Engine Bottom End{Transmission
chapter).
- Drain the cool ant (see Coolant Change in the Coot-
ing System chapter),
eRemove the foll owing parts.
Kick Pedal
Clutch Cable lower End
Brake Pedal
Impeller
. Pull off the water pump hose lower end.
_Remove the right side KIPS cover from the cylinder.
eRemove the shaft lever mounting bolt or nut, and take
off the shaft lever.
m
unON
]
oExhault valve operating shaft lever nut for the
KX125 has laft-hand threads.
10(126:
10(260:
KX500:
A. Shaft l ever
- For KX125 model ; turn the clutch release lever
toward the rear and free the release shaft from the
clutch spring plate pusher.
- Take off the oil filler cap and remove the ri ght
engine cover.
Right Engine Cover InstBIIBtion Notes
- Installation is the reverse of removal. Note the
foll owing.
- There are two knock pins on the mating surfaces of
the crankcase and right engi ne cover.
-I n case the exhaust advancer assembly has been
removed, install it and turn the gear so as to level
the gear drive pin.
011 the gear drive pin Is not positioned level, it may
1all out when Installing the right engine cover.
A. Gear Drive Pin (level position)
- For KX125 model ; turn the cl utch release lever to-
ward the rear.
- Install the right engine cover using the kick shaft
oil seal guide (special tool) to protect the cover
oi l seal.
A. Kick Shaft Oi l Sea l Guide: 57001-263
- Fit the shaft lever boss in the groove of the valve
operating (ad col la r. and install the shaft lever on
the lever shaft. Tighten the shaft lever mounting
bolt or nut to the specified torque.
Tightening Torque
"KX,26 INutl : 8.3 N-m 10.86 kg-m. 741n-lbl
KX250 {Nutl : 9.S N-m (1 .0 kg-m. 87 in-Ibl
KX600 IBoItI : 9.8 N-m (1 .0 kg-m. 87 In-Ibl
*: Left-hand threads
NOTE
o Tighten the shaft lever mounting bolt while holding
the valve operatjng rod all the way in.
A. Shaft l ever C. Collar
B. Boss D. Valve Operating Rod
- Tighten the following pa rts to the specified torque.
Right Engine Cover Bolts:
9 .8 N-m 11 .0 kg-m. 87 in-Ibl
Water Pump Impeller Bolt:
6.9 N-m 10.7 kg-m. 61 in-fbi
- Apply grease to the inside of t he brake peda l boss.
- Tighten t he brake pedal mounting bolt to the speci-
fied torque.
Tightening Torque
8.8 N-m (0.9 kg-m. 78 in-Ibl
- Fill the cooling system (see Coolant Fil ling in the
Cooling System chapter).
- Fi ll the transmission with oi l (see Transmission Oi l
Change in t he Engine Bottom EndfTransmission
chapter).
- Adjust the following parts.
Clutch Cable
Rear Brake
Right Engine Cover Disassembly
- Remove the ri ght engine cover.
- Turn the lever shaft to the right. a nd remove the ex-
haust advancer assembly.
- Remove the Allen bolts. and take off the advancer
lever.
KX'26:
KX250:
5 8 ENGINE RIGHT SIDE
KX500:
A. lever Shaft C. Allen Bolts
B. Exhaust Advancer Assembly
- Remove the plug screw and take out the pos ition
ing pin.
- Pull the lever shaft out of the right engi ne cover.
!
8
A. Plug Screw C. l ever Shaft
B. Positioning Pin
-Pull off the water pump shaft (see Water Pump
Shaft Removal in t he Cooling System chapter).
KX125:
000 not remove the clutch release shaft unless it
I. absolutely necessary. If removed. you must
replace the oJl Hal with. new one.
A. Clutch Re lease Shaft B. Oi l Seal
Exhaust Advancer Assembly
Disassembly/Assembly Notes
- The exhaust advancer assembly consists of the
foll owing parts.
A. Exhaust Advancer Assembly
1. Pins
2. Rod
3. Guide
4. O-ring
5. Steel Balls
6. Holder
7. Needle Bearing
B. Spacer
9. Collar
10. Collar
11 . Spring
12. Gear
- Check the exhaust advancer assembly parts for
damage. Any damaged parts should be replaced
with new ones.
- when assembling, apply molybdenum disulfide
grease between the rod and holder.
Right Engine Cover Assembly Notes
- For KX125 model; in case of the clutch release
shaft has been removed, be sure to replace the
oil seal with a new one and apply high temperature
grease liberal ly to the oil seal lip.
eApply high temperature grease to the oil seal lips
before inserting the lever shaft.
eApply molybdenum disulfide grease to the surface of
the lever shaft, and insert the lever shaft into the right
engine cover hole.
eTighten the advancer lever mounting All en bolts to the
specified torque.
Tightening Torque
3 .9 N-m 10.4 kg-m, 35 in-Ib)
- Fit the adva ncer lever pin into the groove on the
exhaust advancer assembly, and install the as-
sembly in the engine cover while turning the lever
shaft to the left.
A. Exhaust Advancer Assembly C. Pin
B. Advancer Leve r D. Groove
-Tighten the exhaust valve advancer shaft plug
screw to t he specified torque.
Tightening Torque
2 .0 N-m 10.2 kg-m. 17 In-Ibl
5 '0 ENGINE RIGHT SIDE
Clutch
Proper clutch lever play between the clutch lever
and the clutch lever holder is 2-3 mm. Play in-
crease with cable stretch and friction plate wear,
necessitating adjustment. When there is too much
lever play, first try adjusting the cable at the clutch
lever.
I WARNING'
oTo avoid a serious burn. never touch the hot
engine or exhaust chamber duri ng clutch adjust-
ment.
Clutch Adjustment
- Slide the clutch lever dust cover out of place.
- loosen the knurled locknut, turn the adjuster to
obtain the proper amount of lever play, and tight-
en the locknut.
A. Clutch lever
B. Knurled locknut
C. Adjuster
D. Clutch lever Free Play 2 - 3 mm
Slide back the dutch lever dust cover.
* If the adjuster at the dutch lever has reached its
limit, adjust the cable with the adjusting nut at
the upper of the clutch cable.
- loosen the knurled locknut at the clutch lever.
- Turn the adjuster in all the way, then tighten the
knurled locknut.
- loosen the locknut at the upper of the cable, and
turn the adjusting nut so that clutch lever has
2 - 3 mm of play.
A. Adjusting Nut B. locknut
- Tighten the locknut.
- Slide the dust cover back into place.
- After the adjustment is made, start the engine and
check that the clutch does not slip and that it re-
leases properly.
Clutch Removal/Disassembly
- For KX125, 250 model; remove the clutch cover.
A. Clutch Cover B. Clutch Cable
- For KX125 model ; remove the clutch cable.
- For KXSOO model; remove the right engine cover (see
Right Engine Cover Removal).
KX125:
- Remove the ftat washer and cl utch pusher in the
clutch hub.
A. Clutch Pusher B. flat Washer
- Remove the magneto cover.
- Use the rotor holder and adapter " AU (special tools)
to prevent the clutch from rotating, loosen the
clutch hub nut (see Electrical System chapter).
- Remove the clutch springs and spri ng pla te.
- Reinstall the spring bolts with washers (Part
Number: 92022.1(19).
A. Washer: 92022-1619 B. Clutch Hub Nut
- Remove t he clutch hub nut.
- Remove the clutch assembly, needle bearings,
sieeve and t hrust washer.
~ ~ 1 W I I I I l
A. Needle Bearings B. Sleeve C. Thrust Washer
ENGINE RIGHT SIDE 5-1 1
KX250, 500:
- Remove the magneto cover.
- Usi ng the rotor holder and adapter " A" (special
t ools) to prevent the clutch f rom rotating, remove
the clutch spring bolts and springs (see Electri cal
System chapter).
~ . ~ ~
A. Clutch Spri ng Bolts
- Remove the clut ch pressure plate, push rod holder,
flat washer, friction plates, steel plates, and push
cod.
_For early model ; straighten the side of the toothed
washer.
- Use t he clutch holde r (specia l tool) to preve nt the
clutch hub from rotating.
A. Cl utch Holde r: 57001-1243
- Remove the clutch hub nut and washer.
- Remove the clutch assembly, needle bearing,
sleeve, and thrust washer.
A. Needle Bearing C. Thrust Washer
B. Sleeve
5- 12 ENGINE RIGHT SIDE
Clutch Installation Notes
-I nstallation is the reverse of re moval.
- Apply molybdenum disulfide grease to the outside
of the sleeve.
- Apply transmission oil to the inside of the cl utch
housing gear and kick starter driven gear.
- Install the friction plates and steel plates, starting
with a friction plate and alternati ng them. Finishing
with a fricti on plate.
_For KX12S model, the inside diameter of one of the
friction plate is larger than the others. Install it with
the spring and spring seat as shown below. Spring
concave side must be faced inside.
, . The inside diameter is larger than others.
2. Spring Seat
3. Spri ng
!CAUTlm
ott dry steel plate. and friction pl l t H are hmalled, Ipply
tr. nunlulon oil to the surface. of lach pllte to I void
clutch pl.te seizure.
- For KX250. 500 model; install the toothed washer
50 that the teeth align with the projection on the
clultch housing.
- For the KX125 model; apply a small amount of non-
permanent locking agent to the clutch hub nut.
_For KX250, 500 earl y model; bent the side of the
toothed washer to prevent the clutch hub from
rotation.
_Tighten the clutch hub nut to the specified torque.
Tightening Torque:
KX125: 78 N-m (8 kg-m. 58 ft-Ibl
KX250. 500: 98 N-m 110 kg-m. 72 It-Ibl
_For the KX250 model ; set the push rod bushing as
the following procedures.
oMeasure the height (Owhich the bushi ng protrudes
from the shaft end.
1. Bushing
2. Push Rod
aU t he height is 1.5 mm or less than it. investigate
other cause than the bushing.
cif the height is more than 1.5 mm, press the
bushing into the t ransmiss ion shaft by lightly
tapping the bushing with a brass hammer unti l the
height is 1.5 mm. Be careful not to deform the
bushing end.
011 the bushing I. pre ed in .0 1ar thet the height
reduce. Ie than 1.5 mm. the inner chamfered
end 01 bushlng ride. over the stepped portion of
the input .haft and the In.lde diameter 01 bu. h-
Ing reduce . In this case the pu.h rod cannot be
in.erted Into the b u ~ n g or allde. with dragging.
oAfter pressing into the bushing. insert the push rod
into the input shaft. Check if the push rod can slide
smoothly. Light dragging can be cured by sanding
the push rod surface by sand paper.
- Apply mol ybdenum disulfide grease to the clutch
spring plate pusher.
- Tighten the dutch spring bolts to the specified
torque.
Tightening Torque:
9.3 N-m (0.95 kg-m. 82 In-Ibl
Friction Plate Wear, Damage Inspection
- Visually inspect the friction 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 the friction plates with
vernier calipers.
* If they have worn past the service limit. replace them
with new ones.
Friction Plata Thk:knesa:
Standard: 2.92 - 3.08 mm
Service Umlt: KX125: 2.7 mm
KX250, 500: 2.8 mm
Friction Plate Thickness Measurement
1. Friction Plate
Friction and Steel Plate Warp Inspection
Place each friction plate or steel plate on a surface
plate, and measure the gap between the surface
plate and each friction plate or steel plate. The
gap is the amount of friction or steel plate warp.
* If any plate is warped over the service limit, reo-
place it with a new one.
Friction and Steel Plate Warp
Standard:
Service Limit:
not more than 0.15 mm
0.3 mm
Friction and Steel Plata Warp Measurement
CD
1. Plate 3. Surface Plate
2. Thickness Gauge
Clutch Spring Free Length Measuremen t
- Since the spring becomes shorter as 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.
Clutch Spring Free Langth
Standard:
Service Umit :
KX125: 39.4 mm
KX260: 33.3 mm
KX600: 32.6 mm
KX126: 37.9 mm
KX250: 31 .6 mm
KX600: 31 .1 mm
ENGINE RIGHT SIDE 5 13
A. Clutch Spring
Fricti on Plate/Clutch Housing Clearance
- Measure the clearance between the tangs on the
friction plate and the fingers of the clutch housing.
* If this clearance is excessive, the clutch will be noisy.
* If the clearance exceeds the service limit. replace
the friction plates.
Friction PlatelClutch Housing Clearance
Standard:
Service Umit:
0.35 - 0.60 mm
0.9 mm
Friction Plate
Clutch Hub Spline Inspection
-Visually inspect where the teeth on the steel plates
wear against the splines of the clutch hub.
* If there are notches worn into the splines, replace
the clutch hub. Also, replace the steel plates jf their
teeth are damaged.
A. Cl utch Hub Spline
5-14 ENGINE RIGHT SIDE
External Shift Mechanism
External Shift Mechanism Removal
Shift Pedal
Magneto Cover
Right Engine Cover
Clutch Housing
. Pull out the shift shaft with the shift mechanism
arm and arm spring. and remove the return spring.
A. External Shift Mechanism
B. Neutral Set Lever
C. Spring
- Remove the bolt. and take off the neutral set
lever.
External Shift Mechanism Installation Notes
-I nstall ation is the reverse of removal.
-I nsert the shift shaft into the crankcase using the
shi ft shaft oil seal &uide (special tool) on the oil
seal in the left crankcase half to protect the seal.
oBefare installing the shift shaft, apply high temper-
ature grease to the oil seal lips.
A. Shift Shaft Oi l Seal Guide: 57001-264
External Shift Mechanism Inspection
Examine the shift shaft for any damage.
o Check the shift shaft for bending or damage to the
spli nes.
'* If the shaft is bent, straighten or replace it If the
splines are damaged, replace the external shift
mechanism.
o Check the retum spring and arm spring for cracks
or distortion.
,*If the springs are damaged in any way. replace them.
o Check the shift mechanism arm for distortion.
'* If the shift mechanism arm is damaged in any way.
replace the external shift mechanism.
o
A. Shift Shaft C. Arm Spring
B. Return Spring D. Shift Mechanism Arm
Check that the return spring pin is not
loose.
* If it is loose. unscrew it, apply a non-permanent
locking agent to the threads, and tighten it to the
specified torque.
Tightening Torque
KX1 25. 250: 22 N-m 12.2 kg-m. 16_0 ft-Ibl
KX500: 20 N-m(2.0 kg-m. 14.5 ft-Ibl
Check the neutral set lever and its spring for
c racks or distortion.
* If the lever or spring is damaged in any way,
replace them.
Primary Gear
Primary Gear Removal
- Remove the right engine cover (see Right Engine
Cover Removal).
- Remove the clutch (see Clutch Removal).
e For KX125 model; remove the primary gear nut, spring
washer, woodruff key, primary gear, and D-ring.
A. Primary Gear Nut
- For KX250. 500 model; remove the cirdip, and
take off the primary gear.
KX250:
A. Ci rclip
B. Water Pump Drive Gear
C. Primary Gear
KX500:
A. Ci rcl ip
B. Water Pump Drive Gear
C. Primary Gear
Primar y Gear Installation Notes
-Install ation is the reve rse of removal.
_For the KX125i do the following.
oFit the woodruff key on t he crankshaft groove.
olnstaJl the spring washer 50 that concave side faces
inward.
A. Concave Side
OTighten the primary gear nut to the specif ied torque.
Tightening Torque
59 N-m 16.0 kgm. 43 ft lbl
- For KX250; install the primary gear so that cham
fe red side faces outward.
5-16 ENGINE RIGHT SIDE
A. Chamfered Side
eFor KX250, 500; replace the old ci rclip with a new
one.
Klckstarter
Kickstarter Assembly Removal
Right Engine Cover
Clutch Housing
. Pull the end of the kick spring out of the hole in
the crankcase.
KX126:
A. Kick Spring
B. Kickstarter Assembly
KX260:
A. Kick Spring
C. Ratchet Guide
O. Bolts
C. Ratchet Guide
D. Bolts
KX500:
A. Kick Spring
C. Ratchet Guide
D. Bolts
- Remove the ratchet guide and bolts.
- Remove the kickstarter assembly_
Kickstarter Assembly Installation Notes
-Install ation is the reverse of removal.
- Apply a non-permanent locking agent to the threads
of the ratchet guide bolu.
Kickstarter Assembly
Disassembly/ Assembl y Notes
- The kickstarter assembly consists of the following
parts.
- Check the kickstarter assembly parts for damage. Any
damaged parts should be replaced with new ones.
3
1. Idle Gear 5. Spring
2. Circlip 6. Kick Shaft
3. Kick Gear 7. Kick Spring
4. Ratchet Gear 8. Spring Guide
ENGINE RIGHT SIDE 5- 17
[
oWhen assemblng the ratchet gear onto the klck
shaft. aIgn the punch mark on the ratchet gear with
the punch mark on the kick shaft.
A. Kick Shaft C. Punch Marks
B. Ratchet Gear
- Apply molybdenum disulfide grease to the inside of
the kick gear and ratchet gear.
- Repl ace t he drclips 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 gear circlip and pull off the idle
gear.
A. Id le Gear B. Circlip
Kicks rarter Idle Gear Installation Notes
- Installation is the reverse of removal (see Right Engine
Cover Installation Notes and Clutch Install ation Notes).
- Apply molybdenum disulfide grease to the inside of
the idle gear.
- Replace the ci rdip that was removed with a new one.
, ,
, .
- 1
., -
, .

,
ENGINE REMOVALIINSTALLATION 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/INSTALLA TION
..... ...... ............ .. ... .... ............... . ... ........
Exploded View
... .......................... ............ ............... .....
r------------------,
I T1 I KX125
Model
I I
I I
I I
I I
I
I
I
I
I
I
I
I
L ________ ---""
/
/
/
T1 : 25 N-m (2.6 kg-m. 19.0 ft-Ibl
T2: 78 N-m (8.0 kg-m. 58 fNb)
.P
,,'
"
KX250. 500 Mod.1
/
/
/
/
/
/
/
/
r- -- - ------- - ---,
//" T1 :
/ I
/ I
// I
/ I
// ~ I
( ' < J ~ 1
I \ ' I
I , I
I I
I I
i ~ /:
I /
I /
I ~ /
I QJ) ///
~ /
- T1 "
--- ./
- /
----- - --_/
Engine Removal /Installation
Engine Removal
- Drain the transmission oil (see Transmission Oi l
Change in the Engine Bottom End{Transmission chap-
ter).
- Drain the coolant (see Coolant Change in the Cool-
ing System chapter).
- Remove the foll owing parts.
Right and Left Side Covers
Radiator Cover
Seat
fuel Tank
Expansion Chamber
Spark Plug
Cooling Hoses
Carburetor (with Cables and Hoses)
Clutch Cable Lower End
Drive Chain and Engine Sprocket
Shift Pedal
Brake Pedal
-Disconnect the magneto output lead, and free the
leads from the frame.
-Remove the engine brackets and mounting bolts.
A. Magneto Lead
B. Engine Bracket
C. Engine Bracket Mounting Bolts
- Place a stand under the frame to lift the motorcycle
off the ground, and put blocks under the front and
rear tires to steady the motorcycle.
I WARNING'
oThe swing ann pivot shaft also serves as the engine
mounting batt. Take precautions to insure the frame
is weU supported, and that the motorcycle will not
fall over when the pivot shaft is removed.
ENGINE REMOVAL/INSTALLATION 6-3
- Remove the engine mounting bolts.
-Pullout the swing arm pivot shaft
-lift the engine out to the right.
A. Stand
B. Engine Mounting Bolts
C. Swing Arm Pivot Shaft
Engine Installation Notes
-Engine installation is the reverse of removal.
-Tighten the nuts to the specified torque.
Tightening Torque
Engine Mounting Nuts :
25 N-m (2.6 kg-m. 19 ft -Ibl
Engine Bracket Mounting Nuts:
25 N-m (2.6 kg-m. 19 ft -Ibl
Pivot Shaft Nut :
78 N-m (8.0 kg-m. 58 ft -Ibl
- To route the leads, cables and hoses, refer to the
General Information chapter.
-To install parts removed, refer to the appropriate
chapters.
-fill the engine with coolant (see Coolant Change in
the Cooling System chapter).
- Fi ll the engine wi th transmission oil (see Transmission
Oil Change in the Engine Bottom End/Transmission
chapter).
- Adjust the following parts:
Throttle Cable
Cl ut ch Cable
Drive Chain
Rear Brake
ENGINE BOTTOM END/TRANSMISSION 7 '
Engine Bottom End/Transmission
Table of Contents
Exploded View .......................... . .............. . ... ...... .. .................. .. 7-2
Specifications ................ . ... . .. ... .. ... . ....... ... . .. ..................... ........ 7-5
Special Tools ... .. . ....... ..... .. .... ... . . .. . .. . .. ... ..... . . .. . .... ... .. ... ....... . 7-6
Transmissi on Oil . ..... . .... .. ................. .. ......... ... .. . . . ",.... . ..... . ........ 7-7
Oil Level Inspection ....... .. ............ .... ..... ...... . .... . .. .. .............. 7 7
Oil Change .. . .. ... . . ........... ......... . ... . ..... ... . ... .. ............. ...... ... . 7-7
Crankcase Splitting . ... .............. .......... . .. . ....... . ......................... 78
Crankcase Splitting ........... ..... . ............... ........... ........... ... 7 8
Crankcase Assembly .. ........... .. ..... .. .. . .. .. ...... .. .. .. .. . . ....... . ..... 79
Crankshaft , Connecting Rod ........ . ... . ............... . ........... . ........... 711
Crankshaft Removal .. ..... .. . .. ...... . .. .. .. ....... .......... ..... ... . . ... .. 71'
Crankshaft Installation Notes .... .. ....... ..................... . .. .... . ... 71'
Crankshaft Disassembl y Note .... ... .. .. .. . ... .. .. .......... .. ... .. ...... 711
Crankshaft Assembly Notes .............................................. 7-'2
Connecting Rod Big End Radial Clearance ............ .. ............. 7 12
Big End Seizure ................ .. ................... . ......................... 7- '2
Connecting Rod Big End Side Clearance .. ..... .. .... ...... .... ...... 7'2
Crankshaft Runout .... .. . ... .. ..... . ... .. . .. .. .. . .. . .. .. . .. . .. .. .. .. . ..... . 712
Crankshaft Alignment .... .. . ......... ... ............. . .................. . ..... 7'3
Transmission ......... . ......... .... .. .. ......... .. . .... . ........ ... . ... . .. ..... . .. ..... 7- 14
Transmission Shaft Removal .............. ....... .. ............... . ........ 714
Transmission Shaft Installation Notes .. .. .... .... .... .. .. .... .. . .. ...... 7 14
Transmission Shaft Disassembly Notes .... .................. .. ... ...... 7 '4
Transmission Shaft Assembly Notes ................ .. ........... . ...... 7'4
Shift Drum and Fork Installation Notes . .. ........ .......... .. ...... .. .. 7- 16
Shift Fork Bending . .. .............. . .. . . ... .... ......... . ................ . .... . 7 17
Shi ft Fork/Gear Groove Wear ................................. ....... ...... 7-17
Shift Fork Guide Pin/Shift Drum Groove Wear .. ............... .... .. 7 18
Gear Damage ......... . ........... .. . ... . .............. . . .. .......... .... . ....... 7 18
Gear Dog/Gear Dog Hole Damage ...... .. ........... .. ................... 7-18
Bal l Bearing Wear . ......... . .. ........................ . .... .. ..... .. ... . ..... .. 7 19
DITRANSMISSION
7-2 ENGINE ... .. .. ... . .. . .... . .. ... ... . .. .. .
BOTTOM EN .. ..
.... .. ....... .
.......... d View .. . .. . ... . .. .. .. ... .. . .. ...... . .
Explode .... ..... .
................
KX125:
y!
~ ~
~ b
~
/
anent locking av-nt.
l : Apply. no=m diautflde gr .....
M . Apply moly 62 In-Ib) ~
T 1: 6.9 N' m (0.8 kg-Jn. 87 In.lbl
T2; 9.8 N-m 1 1 . ~ ~ : : : : 871n-lbl
T 3 : 9.8 N-m 11. It: -nt. 14.6 ft-tbl
T 4 ' 20 N-m 12.0 : -In 87 In-lbl
5 : 9.8 N'm 11 .0 g '16.0 h-lbl
T . (22 kg-m,
TO: 22 N-m .
KX250:
l : Apply a non-permanent locking agent .
f1 : 5.9 N-m (0.6 kg-m. 52In-lb)
T 2: 9.8 N-m 11.0 kg-m. 87 In-Ib)
T 3 : 9.8 N-m 11.0 kg-m. 87 in-Ib}
T4: 20 N-m 12.0 kg-m, 14.5 ft -Ib)
T5: 9.8 N-m 11.0 kg-m. 87 In-Ib)
T6: 22 N-m (2.2 kg-m. 16.0 ft -Ib)
ENGINE BOTTOM ENOITRANSMISSION 7-3
7-4 ENGINE BOTTOM ENO/TRANSMISSION
KX500:
l : Apply. non-J*menent locking egent.
T 1: 5.9 N' m (0.6 kg-m, 62 In-lbl
T 2 : 9.8 N-m 11.0 kg-m, 87 In-lbl
T3 : 20 N' m {Z.O kg-m. 14.6 ftlbl
T4: 22 N' m 12.2 kg-m. 18.0 ft-Ibl

Specifications
Item Standard Service limit
Transmission Oil :
Grade SE class - --
Viscosity SAE 10W 30 or 10W 40 ---
Amount : KX 125 0. 65 L ---
KX250, 500 0.8 L - --
Crankshaft. Connecting Rod:
Connecting rod:
Bend and twist not more than O.03mml O.20mm/ l00mm
100mrn
Big end radial clearance:
KX125 0.026- 0.043 mm 0. 10 mm
KX250 0.037 - 0.049 mm 0.10 mm
KX500 0.033-0.049 mm 0. 10 mm
Big end side clearance:
KX125, 500 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
KX500 under 0.03 mm 0. 10 mm
Transmission:
Gear backlash 0.02- 0. 19 mm 0. 26 mm
Shift fork finger thickness: KX125 3.9-4.0 mm 3.B mm
KX250, 500 4.4-4. 5 mm 4.30 mm
Gear shift fork groove width:KX125 4.05-4. 15 mm 4 .25 mm
KX250,500 4.55-4. 65 mm 4.75 mm
Shift fork guide pin diameter 5.98-6.00 mm 5.88 mm
Shift drum groove width 6.05-6.20 mm 6.25 mm
7-6 ENGINE BOTTOM ENOITRANSMISSION
Special Tools
.. ..... ... .............. . ........ .. ..... ................... ..
Along with common hand tools and precision
instruments. speciali zed tools are required for com-
plete crankshaft/transmission servicing.
Clrcllp P1lers: 57001-144
Crankshaft Jig: 57001 1174

Bearing Drive, Set: 57001, ' 129
Kick Shaft 011 Seal Guide: 67001 -263
Shift Shaft 011 Seal Guide: 57001 264
Bearing Puller : 67001 158
Crankcase SpNttlng Tool Set: 5700' -'098
Adapter: 57001 136
Transmission Oil
In order for the transmission and clutch to function
properly, always maintain the transmission oil at the
proper level and change the oil periodically.
I WARNING'
oMotorcycle operation with insufficient, deteri-
orated, or contaminated transmission oil will
cause accelerated wear and may result in trans-
mission seizure, accident, and injury .
Oil Level Inspection
- Situate the motorcycle so that it is perpendicular
to the ground.
- rf the motorcycle has just been used, wait several
minutes until the oi l settles.
- Check that the oi l level comes up between the upper
and lower levels through the oi l level gauge on the
right engine cover.
KX125:
KX250:
KX500:
A. Oil Level Gauge C. lower level
B. Upper level
.. If the oi l level is too high, remove the excess oil
removing the drain plug.
* If the oil level is too low, add the correct amount
of oil through the oil filler opening. Use the same
type and make of oil that is already in the engine.
NOTE
oJ! the transmission oil type and make are unknown,
use any brand of the specified oil to top up the level
in preference to running the engine with the oil level
/ow. Then at your earliest convenience, change the
oil completely.
Oil Change
- Warm up the engine thoroughly so that the oil will
pick up any sediment and drain easily. Then stop
the engine.
-Pl ace an oil pan beneath the engine.
- Remove the transmission oil drain plug on the bottom
of the engine, and let the oil drain completely.
NOTE
0Hold the motorcycle upright so that the 011 may
drain completely.
KX125:
7-8 ENGINE BOTTOM ENDITRANSMISSION
KX250,
KX500,
A. Transmission Oil Drain Plug
Check the gasket at the drain plug for damage.
* Replace the gasket with a new one if it is damaged.
After the oi l has completely drained out, install the
drain plug with the gasket, and tighten it to the
specified torque.
TIghtening Torque:
20 N-m 12.0 kg-m. 14.5 ftlb)
Fill the engine with a good quality motor oil
specified in the table.
Check the oil level.
Transmission 011
Grade: SE class
Viscosity: SAE 10W30 or 10W40
Amount: KX125: 0.66 L
KX250.500, 0.8 L
.. ........... .. ........... ....... ... .... ... ... ................
Crankcase Splitting
........ ......... .............................................
Crankc8se Splitting
- Remove the engine (see the Engine Removalflnstal
lation chapter).
- Set the engine on a dean surface while parts are
being removed.
- Remove the following parts from the engine:
Magneto Cover
Output Shaft Sleeve and O-ring
Cylinder Head
Cylinder
Piston
Right Engi ne Cover
Cl utch
Primary Gear
Kickstarter Assembly
Kickstarter Idle Gear
Neutral Set lever
Magneto Flywheel and Stator
Reed Valve (KX125)
.Remove the crankcase bol ts.
KX125,
KX250,
KX600,
A. Crankcase Bolts
-I nstall the crankcase splitting tool and adapter
(special tools) into the left side of the crankcase.
Be certain to screw the tool in all the way.
A. Crankcase Splitting Tool Set: 57001-1096
B. Adapter: 57001-136
- Tighten the bolt on the crankcase splitting tool
to split the crankcase halves.
-Once the crankcase is split. remove the crankcase
splitting tool. and lift off the left crankcase.
- Remove the shift rods, shif t forks. shift drum, and
output and drive shaft assemblies.
A. Drive Shaft D. Shift Drum
B. Output Shaft E. Shift Forks
C. Shift Rods
- Remove the breather hose from the right crank-
case half.
- Remove the crankshaft from the right crankcase
half usi ng a press.
Crankcase Assembly
- Before fitting the left case on the right case, note
the following. .
OChip off the old gasket from the mating surfaces of
the crankcase halves, and clean off the crankcase
with a high flash-point solvent. After cleaning,apply
transmission oi l to the transmission gears, shift
drum, shift forks and so on.
oBe sure to replace any oil seal removed with a new
one. Press in the new oil seal using a press and
sui table tools so that the seal surface is flush with
the surface of the crankcase.
oApply high temperature grease to the oil seal lips.
oPress in the ball bearings using the bearing driver
set (special tool: 57001-1129) until the bearing is
bottomed.
of or KX125; install the bearing for the output shaft
into the left crankcase half so that the stepped side
faces inside.
1. Stepped Side
7-10 ENGINE BOTTOM ENO/TRANSMISSION
NOTE
000 nor remove the bearings unless it is necessary.
Removal may damage them.
olnstall the bearings for the crankshaft in the right
and left crankcase so that their sealed sides face
toward the oil sea/ side.
Olighten the output and drive shaft bearing re-
taining bolts to the specified torque.
TIghtening Torque
Output Shaft aearing
Retaining Botts: 5.9 Nm (0.6 kg-m. 52 in-Ib)
Drive Shaft Bearing
Retaining Bolt.: 9.8 N-m 11 .0 kg-m. 871n-lbl
it If the crankshaft bearings stay on the crankshaft
when splitting the crankcase. remove the bearings
from the crankshaft and reinstall them in the
crankcase. arid then assemble the crankcase (see
Crankshaft Removal and Installation Notes) .
Turn the crankshaft to SDC. and install the crank-
shaft jig (special tool) between the flywheels
opposite the connecting rod big end to protect
flywheel alignment as shown.
o If the crankshaft has been removed from the
crankcase, install the crankshaft jig (special tool)
between the crankshaft flywheels before pressing
the crankshaft into the right crankcase half.
A. Crankshaft Jig: 57001-1174
' Check to see that the crankcase knock pins are in
place on the right crankcase hatf. If any of them has
been removed. replace it with a new one.
'Apply liquid gasket to the mating surface of the left
crankcase half.
' Using a suitable tool on the left crankcase to press
around the hole for the crankshaft, fit the crankcase
halves together with a press on the tool.
NOTE
OConstently ChBCk the elignment of the two crenkcese
helves, and the position of the trsnsmission shefts,
lind shift drum. The front end reer of the crankcase
must ba pushed together evenly.
A. Press
Remove the crankshaft jig (special tool) from the
flywheel s.
Tighten the crankcase bolts to the specified torque
starti ng with the ones around the crankshaft, and
then the farther ones.
Tightening Torque
9.8 N-m (1.0 kg-m. 87 in-I b)
Check to see that the crankshaft, drive shaft, and
output shaft all turn freely (i n 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 properl y.
, Install the parts removed in the reverse order of
removal. and refer to the appropriate chapters.
o Replace the O-ring on the output shaft with a new
one.
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 Puller: 57001-158
B. Adapter: 57001-136
Crankshaft Installation Notes
- Installation is the reverse of removal (see Transmission
Shaft Installation Notes and Crankcase Assembly).
-When installing the crankshaft bearings, apply high
temperature grease to the outer sides of the bearings,
and then press them into the crankcase using the
bearing driver set (special tool) until the bearing
bottoms against the step.
A. Bearing Driver Set: 57001-1129
ENGINE BOTTOM ENDITRANSMISSION 7-1 1
A. Bearing Driver Set: 57001-1129
- Insert the crankshaft jig (special 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 the jig in the crankcase
opening so the jig does not hit the crankcase.
A. Crankshaft Jig: 57001-1174
-Apply 2-stroke oil to the connecting rod big end
bearing.
Crankshaft Disassembly Note
Since assembly of the crankshaft demands exacting
tolerances, the disassembly and reassembl y of the
crankshaft can only be done by a shop having the
necessary tools and equipment
elf it should be necessary to disassemble the crank-
shaft. use a press to remove the crank pin.
7- 12 ENGINE BOTTOM ENO/TRANSMISSION
Crankshaft Assembly Not es
Since the assembly of the crankshaft demands ex-
acting tolerances. the disassembly and reassembly of
the crankshaft can only be done by a shop having
the necessary tools and equipment.
- Reassemble the crankshaft accordi ng to the standard
tolerances in Specifications.
OConnecting rod bend, twist
OConnecting rod big end radial clearance.
OCold-fitting tolerance between crankpin and fly-
wheels.
OSide clearance between the connect ing rod big
end and one of the fl ywheels.
OCrankshaft runout
Connecting Rod Big End Radial Clearance
Set the crankshaft in a flywheel ali gnment jig 01" on
V blocks, and place a dial gauge agai nst the connect-
ing rod big end.
Push the connecting rod first towards the gauge and
then in the OJliXlSite direction. The diHerence be-
tween the two gauge readings is the radial clearance.
*If the radi al clearance exceeds the service limit.
the crankshaft should be either replaced or disas-
sembled and the crankpin, needle bearing, and con-
necting rod big end examined for wear.
Connoc:1g Rod BIg End _ a...nc:e
Standard:
IKX1261
IKX2601
IKX5001
S.Nk:_ Limit:

0.026 - 0.043 mm
0.037 - 0.049 mm
0.033 - 0.049 mm
0. 10 mm
Big End SeiZure
* In case of serious seizure with damaged flywheels,
the crankshaft must be replaced.
* In case of less serious damage, disassemble the
crankshaft and replace the crankpin, needle bearing.
side washers, and connect ing rod.
Connecting Rod Big End Side Clearance
- Measure the side clearance of the connecting rod
with a thickness gauge.
* If the clearance exceeds the service li mit. replace
the crankshaft.
Coo.-mg Rod BIg End SIde a...nc:e
StandarO: IKX126. 5001 0.40-0.50 mm
IKX2501
Servk:e Umit: 0.70 mm
0.45- 0.55 mm
"I
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 readi ngs is the crankshaft runout
CnInkahoft Runout
Standard: Not more than O.03mm
_Umit:
IKX125. 2501
IKX5001
0.05 mm
0 .1 0 mm
Crankshaft Runout
7.5 mm
Turn the crankshaft
slowly.
Crankshaft Alignment
7.5 mm
* If the runout at either point exceeds the service limit,
align the flywheels 50 that the runout falls within
the service limit
In the case of horizontal misalignment, which is the
most common, strike the projecting rim of the fly-
wheel with a plastic, soft lead, or brass hammer as
indicated in the figure.
Recheck the runout with a dial gauge, repeat ing the
process until the runout fall s within the service limit
o Vertical misalignment is corrected either by driving
a wedge in between the flywheels 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 flywheel misalignment cannot be corrected by
the above method, replace the crankpi n or the
crankshaft itself.
Horizontal Mlsaignment
OOon' t hammer the flywheel at point " A" .
Vertical Misalignment
r
r-
Q
Q
0
L-
CJ
D-
r r
..P
A O-
'--
Q
'-'4 ENGINE BOTTOM END/TRANSMISSION
Transmission
Transmission Shaft Removal
- Split the crankcase (see Crankcase Splitting).
-Pull off the shift rod. and disengage the shift fork
guide pins from t he shift drum grooves.
- Remove the shift drum.
- Remove the shift forks from the transmission gears.
- Take out the drive shaft and output shaft together,
with their gears meshed.
A. Drive
B. Output Shaft
C. Shift Rods
D. Shift Drum
E. Shift Forks
Transmission Shaft Installation Notes
-Installation is the reverse of removal .
-Hold the drive shaft and out put shaft together, with
their gears meshed, and fit them into the right
crankcase half.
A. Drive Shaft B. Output Shaft
- To install the shift forks and shift drum, see t he Shift
Drum and Fork Installation Notes.
Transmission Shaft Disassembly Notes
Using circlip pliers (special tool : 57001-144) to re-
move the ci rclips, disassemble the transmission
shaft.
Transmission Shaft Assembly Notes
Assembly is the reverse of removal.
Apply transmission oi l liberally to the transmission
shaft. gears and bearings.
Replace any circlips that were removed with new
ones.
OAlways install circl ips 50 that the opening is aligned
with a spline groove, and install toothed washers so
that the teeth are not aligned with the circlip open-
ing. To install a circlip without damage, first fit the
cirdip onto the shaft expanding it just enough to
install it. and then use a suitable gea r to push t he
circli p into place.
Clrclip and Toothed Washer Installation
1. Teeth of Toothed Washer 4. Openi ng of Circlip
2. Toothed Washer 5. Ci rclip
3. Groove of Shaft 6. Shaft
_The drive shaft gears can be identified by size; the
smallest diameter gear is 1st gear, and the largest
is 5th (KX250, 500) or 6th (KX125). Be sure that all
parts are put back in the correct sequence, facing
the proper di rection, and that a ll circiips a nd 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)
KX250,
1. 1st gear (1ST; part of drive shaft)
2. 5th gear (24T; dog recesses face left)
3. 3rd gea r (18T; fork groove goes to the left
side of the gear teeth)
4. 4th gea r (22T; dog recesses face right)
5. 2nd gear (24T; either side may face in)
KX500;
1. 1st gear (16T; part of drive shaft)
2. 5th gear (24T; dog recesses face left)
3. 3rd gear (22T; fork groove goes to the left side
of the gear teeth)
4. 4th gear (22T; dog recesses face right)
5. 2nd gear (20T; either side may face in)
ENGINE BOTTOM ENDITRANSMISSION 7- 15
5 1
_The output shaft gears can be identified by size;
the largest diameter gear is 1st gea r, and the
smallest is 5th (KX250, 500) or 6th (KX125). Be sure
that all parts are put back in the correct sequence
and faci ng the proper direction, and that all circiips
and washers are properly in place.
Output Shaft Gears
KX125,
1. 2nd gear (24T; dog recesses face right)
2. 5th gea r (2ST; fork groove goes to the right
si de of the gear teeth)
3. 3rd gea r (28T; dog recesses face left)
4. 4th gear (26T; dog recesses face right)
5. 6th gea r (25T; fork groove goes to the left si de
of the gear teeth)
6. 1st gear (23T; plain side faces right)
Apply molybdenum disulfide grease.
KX250,
1. 2nd gear (27T; plain side faces left)
2. 4th gear (25T; fork groove goes to the right
3. 3rd gear (25T; dog recesses face left)
4. 5th gear (24T; dogs face right)
5. 1st gear (32T; dog recesses face left)
7-16 ENGINE BOTTOM ENOITRANSMISSION
KX500,
1. 2nd gear (29T; dog recesses face right)
2. 4th gear (21T; fork groove goes to the right
4. 5th gear (19T; fork groove goes to the left side
of the gear teeth)
5. 1st gear (32T; dog recesses face left)
- Check that each gear spins or slides freely on the
transmission shaft without binding after assembly.
Shift Drum and Fork Installation Notes
- Apply a little transmission oi l to the shift fork
fingers, and fit the shift forks into the gear grooves.
Shift Fork Identification
KX125,
Drive shaft 3rd and 4th
gear shift fork
Output shaft 5th gear
shift fork
Output shaft 6th gear
shift fork
fingers are shorter than
those of the other two
shift forks
guide pin goes to left
side of the fingers
guide pin goes to right
side of the fingers

A. Drive Shaft 3rd and 4th Gear Shift Fork
B. Output Shaft 5th Gear Shift Fork
C. Output Shaft 6th Gear Shift Fork
KX250,
Drive shaft
),d
gear fingers are shorter than
shift fork those of the other two
shift forks
Output shaft 4th gear guide pin goes to left
shift fork side of the fingers
Output shaft 5th gear guide pin goes to center
shift fork

A. Drive Shaft 3rd Gear Shift Fork
Drive shaft ',d gear fingers a re shorter than
shift fork those of the other two
shift forks
Output shaft 4th gear guide pin goes to cen-
shift fork te,
Output shaft 5th gear guide pin goes to left
shift fork si de of the fingers
- ,

A. Drive Shaft 3rd Gear Shift Fork
ENGINE BOTTOM ENOITRANSMISSION 7,17
- Tighten the shift drum bearing retaining bolts to
Tightening Torque
9.8 N-m {l .a kg-m. 87 in-Ibl
-Fit the shift fork guide pins into the corresponding
shift drum grooves.
-Tighten the shift drum operating plate bolt to the
specified torque.
Tightening Torque
22 N-m (2.2 kg-m. 16 ft-Ib)
- Apply a little transmission oil to the shift rod, and
sl ide it into the shift forks.
Shift Fork Bending
- Visually inspect the shift forks. and replace any
fork that is bent. A bent fork could cause difficulty
in shifting, or allow the transmission to jump out
of gear when under power.
Shift Fork/Gear Groove Wear
- Measure the thickness of the shift fork fingers,
and measure the width of the shift fork grooves
in the transmission gears.
* If the thickness of a shift fork finger is less than
the service limit. the shift fork must be replaced.
Shfft Fork Finger Thickness
Standard:
IKX125)
IKX250. 5001
Service limit:
IKX1251
IKX250. 5001
3.9 - 4 .0 mm
4 .4 - 4 .5 mm
3.8mm
4.3 mm
7-1B ENGINE BOTTOM ENDITRANSMISSION
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
Standard:
IKX1 251 4.06- 4. 16 mm
IKX250. 5001 4.55 - 4.85 mm
Service Limit:
IKX1261 4.25 mm
(KX250. 6001 4.76 mm
A. Gear Shift Fork Grooves
Shi ft Fork Guide Pin/Shif t Drum Groove Wear
Measure the diameter of each shift fork guide pin,
and measure the width of each shift drum groove.
* If the guide pin on any shift fork is less than t he
service limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: 5.98- 6.00 mm
Service Limit : 5.88 mm
* If any shift drum groove is worn over the service
limi t, the drum must be replaced.
Shift Drum Groove Width
Standard:
Service Limit:
6 .05- 6 .20 mm
6.25 mm
A. Shift Fork Guide Pin B. Shift Fork Fi ngers
A. Shift Drum Grooves
Gear Damage
Visually inspect the gear teeth on the transmission
gears.
* Repair lightly damaged gear teeth with an oi lstone.
The gear must be replaced if the teeth are badly
damaged.
* At t he same time that a gear is repaired or re-
pl aced, the driving gear should also be inspected
and repaired or replaced if necessary.
Gear Dog/Gear Dog Hole Damage
Visuall y inspect the gear dogs and gear dog holes.
* Replace any damaged gears or gears with exces-
sively worn dogs or dog holes.
A. Dog Hole B. Dog
Ball Bearing Wear
Check the ball bearing on both sides of t he shift
drum, drive shaft and output shaft.
o Since the ball bearings are made to extremely
close tolerances. t he wea r must be judged by feel
rather than measurement. Clean each bearing in a
high flash-point solvent, dry it (do not spin the
bearing while it is dry), and oil it wi th t ransmission
oil.
a Spin the bearing by hand to check its condition.
*If the bearing is noisy, does not spin smooth ly, or
has any rough spots, replace it.
ENGINE BOTTOM ENOiTRANSMISSION 7 19
WHEELSfTlRES 8-1
Wheels/Tires
Table of Contents
Exploded View .... . ... ............. . ...... . _ ...... . .. . .............. . ................. .
Specifications
Special Tool s ...... ............. .... .... . .. .. ........ .. .. ................ .... ... .. ..
Wheels . .. ..... ..... ... . .. . .. ..... ... . .. . . ... ......... . .. .. . ..... . .... .. ..... .... .... .
Front Wheel Removal .............. , .......... ............ ...... " ..... _, .. .. .
Front Wheel Installation Not es .. .. ........ .... ........ .................... .
Rear Wheel Removal ... . ......... .. ..... . .. . . .. ..... . .. .. , . .......... .. .. .
Rear Wheel Installation Notes ... ..... . ... . .. . ... ... .. . ... .. .. .. .. . .. , . ... . .
Wheel Alignment Inspection ., .. " ......... . ... .......... . ...... ..... ..... . .
Wheel Alignment Adj ustment .... . ...... .. ................................ .
Wheel Inspection
Spoke Inspection
Rim Inspection .................................................................. .
Axle Inspection .. ........ .. . . ...... . ... .................... ... .. .. .... .......... .
Tires .. ... . .. ... ......... . .. .. .. ........ .. . ............. . .. ...... ... ..... .... ... ....... ... . .
Tire Removal .................... . ... ....................... ... ...... .... ........ .
Tire Installation Notes ..... ..... . .. . .......... .. ....... ....... .... ....... .... .
Tire Pressure Inspection/Adjustment ......... ... .. ....... ... ....... . .... .
Tire Inspection ................... . ...................................... ........ .
Hub Bearing . .......... ... ........ .. ... ... ...... ...... . . .. .. ... ... ... . . .. .. . .. .. .. .. .. .
Hub Bearing Removal Notes ............... .. ............ .. ....... ..... .. .
Hub Bearing Installation Notes ....... .... ............................... .
Hub Bearing Inspection and Lubrication ...... .... .. ............ ..... .
Grease Seal Inspection and Lubrication .................... .... ....... ..
8-2
8-3
8-4
8-5
8-5
8-5
8-5
8-6
8-6
8-6
8-6
m
8-6
8-7
8-7
8-8
8-8
8-8
8-9
8-9
8-1 0
8-10
8-1 0
8-11
8-11
8-2 WHEELSITIRES
Exploded View
T1 : 5' N-rn (5.5 kg-rn, 40 fNb)
T2 : 9.3 N-rn (0.96 kg",", 82 In-4bl
T3 : 26 N-rn (2:.5 kgom, 18 ft-tb)
T4: 98 N-rn (10 kg-rn, 72 f t ~ l
1'5: 1.5 N-rn 10.15 kg",", 13 in-tb)
WHEELS/TIRES 8 3
Specifications
Whoels:
Rim runout : Axial Under 0.5 mm 2mm
Radial Under 0.8 mm 2mm
Axle runout/ l00 rnm Under 0.10 mm O.2mm
10.7 mm: AL)
Tires:
IKX125, 250)
Front: Size 80/ 1oo2151M ---
Make, type DUNLDP K490 DUNLOP K990
---
Rear: Size: KX125 loo/ loo 1859M ---
KX250 110/ loo 1884M
-- -
Make, type DUN LOP K595 DUN LOP K990
- - -
IKX5OO)
Front : Size 80/ 1oo2151M ---
Make, type 8AIDGESTONE M23, DUNLOP K990 ---
Rear: Size 110/ loo1884M
- --
Make, type 8A IDGESTONE M22 ---
Size
120/ 100 18 saM -- -
Make, type DUNLOP K990 ---
Air pressure 100 kPa 11.0 kg/em', 14 psi ) - - -
<E> : European model
8-4 WHEELSITIRES
Special Tools
Bearing Driver Set: 67001 1129
Bead Breaker A .. ' y: 57001-'072
Tire Iron: 67001 -1073
Rim Protector: 570011063
ClrcUp Pliers: 67001143
NOTE
oThe tire irons (PI N 57001 1073) are included in
the bead breaker assembly (PIN 57001 1072J.
Wheels
Front Wheel Removal
_Place a stand or block under the motorcycle so that the
front wheel is raised off the ground.
- Remove the axle clamp nuts, and remove the wheel
with the axle.
_Remove the axle nut, and remove the wheel.
000 I1bt lay the wheel on the ground wrth the disc
facing down. This can damage or warp the disc.
Aace bk>cks under the wheel so the disc does not
touch the ground.
- Insert a wood wedge between the disc brake pads
this prevents them from being moved out of their
proper position. should the brake lever be squeezed
accidentally.
Front Wheel Installation Notes
-I nstallation is the reverse of removal.
- Fit the caps to the both side of the hub.
A. Cap B. Groove
- Tighten the axle nut to the specified torque.
Tightening Torque
54N-m (5. 5 kg-m, 40 ft-lb)
-nle arrow mark on the front axle damps must point
upward.
WHEELSITIRES 8-5
A. Arrow Mark C. lower Clamp Nuts
B. Upper Clamp Nuts
- Tighten the upper damp nuts f irst, and tighten the
lower damp nuts to the specified torque.
TIght_ T"""",
9.3 N-m 10.95 kg-m. 82 In-Ib)
- Check the front brake for weak braking power and
brake drag.
I WARNING'
000 not attempt to drive the until a full
brake is obtained by pumping the brake
until the pads are against the disc. The brake will
not function on the first application of the lever
If this is not done.
Rear Wheel Removal
- Place a stand or block under the motOfcyde so that
the rear wheel is raised off the ground.
- Remove the caliper cover, unscrew the caliper mount-
ing bolts, and remove the caliper from the disc.
-I nsert a wood wedge ' between the brake pads this
prevents them from being moved out of their proper
position, should the brake pedal be squeezed acciden-
tally.
-Remove the clip from the master link using pl iers,
and free the drive chain from the rear sprocket
- Remove the axle nut
- Pull out the axle, and remove the chain adjuster,
brake holder, and rear wheel.
000 not lay the whee' on the ground wJth the disc
Place bkx:ks under the wtM so the disc does not
touch the ground.
86 WHEELSITIRES
Rear Whee/Installation Notes
- Fit the brake holder stop against the swi ng arm stop.
A. Brake Holder C. Swing Arm
B. Stop (Brake Holder) O. Stop (Swina Arm)
- Fit the caps to the irooves on the coll ar.
A. Cap B. Groove
C. Collar
-Install the drive chain. Install the master link dip so
that the closed end of the "u" points in the direc-
tion of chain rotation.
A. Master Link Clip B. Direction of Chai n Rotation
- Adjust the drive chain slack (see Drive Chain Slack
Inspection in the Final Drive chapter).
-Tighten the axle nut to the specified torque.
11ghtonlng Torque
98N-m 110 kg-m. 72 tt-ll'
- The caliper mounting bolts to the specified tOf'que.
T1ghtering Torque
25N-m 12.5 kg-m. 18 f t ~ b
- Check the rear brake for weak braking power and
brake drag.
I WARNING ~
000 not attempt to drive the motorcycle until a fuI
_. pedal Is obtained bV pumping the _. pedal
until the pods ... ogoInot the disc. The _ w.
not fulction on the first applcadon of the pedal
tf this is not done.
Wheel Alignment Inspection
- Refer to Wheel Alignment Inspection in the Final
Drive chapter.
Wheel Alignment Adjustment
-Refer to Wheel Alignment Adjustment in the Final
Drive chapter.
Wheel Inspection
-Place a stand or block under the motorcycle so that
the front/rear wneel is rai sed off the ground.
- Spin the wheel lightly. and check for roughness or
binding.
.. If roughness or bi nding is found. replace or lubri-
cate the hub bearings.
- Visually inspect the front and rear axles fO( damage.
* If axle is damaged or bent. replace it.
Spoke Inspection
- Check that all the spokes are tightened evenly .
If spoke tightness is uneven or loose. tighten the
spoke nipples to the specified torque evenly.
Tlghtonlng Torque:
1.6N-m 10.16 kg-m. 13 in.."
lnot over 3N-m (0.3 kg-m. 26 in Ibl]
- Check the rim runoul
I WARNING.
otf any spoke breaks, it should be replaced immedi-
ately. A missing spoke pklces an additional load
on the other spokes, which wi! eventualy cause
other spokes to break.
Rim Inspection
Inspect the rim for small cracks, dents. bending, or
warping.
* If there is any damage to the rim, it must be re-
placed.
Set a dial gauge against the side of the rim. and
rotate the rim to measure the axial runcut The dif-
ference between the highest and JOINeSt dial readings
is the amount of runout
Set a dial gauge against the outer circumference of
the rim,and rotate the rim to measure radial runout.
The difference between the highest and lowest dial
readings is the amount of runout
* If rim runcut exceeds the limit, check the
wheel bearings first. Replace them if they are
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 recentering the rim.
loosen some spokes and tighten others within the
standard torque to change the position of different
parts of the rim. If the rim is badly bent, however,
it must be replaced.
Rim Runout (with tire instaled)
Standard
Axial under 0.5 mm
Radial under 0.8 mm
A. Axial Rim Runout
S, Radial Rim Runout
Service limit
2 mm
2 mm
WHEELSITIRES 8-7
Axle Inspection
Place the axle in V blocks that are 100 mm apart.
and set a dial gauge on the axle at a point halfway
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 funout only exceeds the service limit straighten
the axle.
* If the axle cannot be straightened to within the
service limit, replace the axle.
Axle Runout/100 mm
Standard: undet' 0 .10 nvn
Service Umit: 0.2 mm
repair Limit: 0.7 mm
Axle Runout
o

88 WHEELSITIRES
Tires
Tire Removal
000 not lav the wheelan 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.
- Remove the wheel from the motorcycle (see Wheels).
- To maintain wheel balance, mark the valve stem
position on the tire with chalk so that the tire can be
reinstall ed in the same position.
-Take out the valve core to let out the air.
A. Unscrew valve core. B. Mark valve stem poSition.
oWhen handling the rim, be careful not to damage
the aluminum rim f langes.
-loosen the bead protector nut.
A. Bead Protector Nut
-lubricate the tire beads and rim flanges on both
sides with a soap and water 50l ution or rubber lubri-
cant This helps the tire beads slip off the rim flanges.
oNeva, lubricate with mineral 011 lenglne 0111 or
gasoline because they will cause deterioration of
the tire.
-Break the beads away from both sides of the rim
with the bead breaker (special tool).
A. Bead Breaker: 570011072
-Pry the tire off the rim with tire irons (special tool)
protecting the rim with rim protectors (special tool).
A. Rim Protectors: 57001-1063
B. Tire Irons: 57001-1073
Tire Installation Notes
- Installation is the reverse of removal (see Wheels).
- Position the tire on the rim so that the valve is at the
ti re balance mark (the chal k mark made during
removal or the yellow paint mark on a new tire).
A. Balance Mark
- Tighten the bead protector nut securely,
- Check and adjust t he ai r pressure after installing.
Tire Pressure Inspection/ Adjustment
- Using tire pressure gauge, measure the tire pressure
when the tires are cold.
*Adjust the ti re presure to suit track conditions and
rider preference, but do not stray too far from the re-
commended pressure.
Track Condition Tire Pressure
QWhen
"'"
track ;,
wet. muddy, sandy 60 kPa [0.8
slippety, reduce
"'"
tire pressure to kg/cm
l
11 psi)
Increase
"'"
tir!! tread surface ,ho
ground.
I
QWhen ,h. track
;,
pebbly
"
hard,
increase ,h. tire pressure
'0
prevent
damage 0. punctures, thQugh ,h. 100 kPa (1 .0
tires will skid more easily, kg/cm
l
, 14 psi)
A. Tire Pressure Gauge
WHEELSITIAES 8-9
Tire Inspection
As the tire tread wears down, the tire becomes
more susceptible the puncture and failure.
- Remove any imbedded stones or other foreign parti-
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 internal damage, requiring tire replace-
ment
I WARNING I
oTo ensure safe handling and stabiity, use only
the recommended standard tires for replacement,
inflated to the standard pressure,
NOTE
oCheck and balance the wheel when a tire is re-
placed with a new one.
Standl,d Tir.
IKX125, 250)
Front : Size SO/1OO2151M
Make, Type DUNLOP K490
DUNLOP K990
Rea' :
Size: KX125 100/10018 S9M
KX250 110/ 1OO1S 84M
Make, Type DUNLOP 1<595
DUNLOP K990
(KX500)
Front: Size SOl 1 002 1 51 M
Make, Type BAIOGESTONE M23
DUNLOP K990
Aeer : Size '10/1001864M
120{100 1868M
Make, Type BAIOGESTONE M22
DUNLOP K990
: European model
8-10 WHEELSITIRES
Hub Bearing
000 not lily the wheelan the ground with the disc
facing down. This can damage or wrap the disc.
Place blocks under the wheel so the disc does
n01 touch the ground.
Hub Bearing Removal Notes
-Remove the hub bearing by tapping evenly around
the bearing inner race as shown.
Bearing Removal
1. Bar
2. Distance Coll ar
3. Hub Bearing
Hub Bearing Installation Notes
- Before installing tile wheel bearings, blow any dirt or
foreign particles out of the hub with compressed air
to prevent contamination of the bearings.
- Inspect the bearings and replace them if necessary.
Lubricate them and install them using the bearing
dri ver set (special tool) so that the marked or shielded
sides face out.
Rear Hub Bearing
A. Bearing Driver Set 57001-1129
1. Bearing Driver Holder
I
2. Bearing Driver
3. Bearing Driver
.I nspect the grease seal and replace if necessary.
Press it in until it stops at the ci rcl ip in the hole
using the same special tools used for bearing in-
stall ation.
Hub Bearing Inspection and Lubrication
Since the wheel bearings are made to extremely
dose tolerances, the clearance cannot normally be
measured_
For front hub bearing, turn each bearing back and
forth while checking for roughness or binding.
* If roughness or binding is found, replace the bearing.
For rear hub bearing, wash the beari ng with a high
flash-point solvent, dry it (do not spin it while it is
dry), and oi l it Spin it by hand to check its condition,
* If it is noisy, does not spin smoothly, or has any
rough spots, it must be replaced.
* If the bearing is to be used again, rewash it with a
quality high flash-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.
NOTE
oSince the bearings on the rear wheel hub are
packed with grease and shielded, they are not be
lubricated.
A. Grease.
Examine the bearing seal for tears or leakage.
* If the seal is torn or is leaking, replace the bearing.
WHEELSITIRES 8-11
Grease Seal Inspection and Lubrication
If the grease seals are examinee! without removing the
seals themselves, look for discoloration (indicating the
rubber has deteriorated), hardening, damage to the
internal ribbing, or other damage. If the seal or internal
ribbing has hardened, the clearance between the seal
and the axle sleeve wi ll not be taken up. which will
allow dirt and moisture to enter and reach the bear-
ing. If in doubt as to its condition and whenever a
seal is removed for greasing the bearing, the seal
should be replaced. The seals are generall y damaged
upon removal.
FINAL DRIVE 9-1
Final Drive
Table of Contents
Exploded View .......................................... .................. ...... . ..... .
Speci fications
Special Tools
Drive Chain .. .. .... ..... ..... . ....................... .. . _._ ....... . .. ....... . ... .... . .. . .
Drive Chain Slack Inspection ............. ........... . .. . .......... .. ...... .
Drive Chain Slack Adjustment .. _ ..................... . ................... .
Wheel Alignment Inspection ............. . .. . ........ _._ .. . .. .. .. ... .. .... .
Wheel Alignment Adjustment . ,_ .. ,_ .. ,_ .. ... _, .... _,_ .. . ....... _._ ...... .
Drive Chain Wear Inspection . .. . ... _ ....... .......... .. .......... . ........ .
Drive Chain Lubrication ..... . ...... .. ...... . _ ..... .. . .. . ...... . .. ... . ..... . .
Drive Chain Removal . . .. .. . .. ... .. .. ... ... . .... .. .. .. .. .. . .. . . .. . ... .... . .. .. .
Drive Chain Installation Notes ............ . ........... . ............ . . ...... .
Sprocket ...... . ....... . .... . .. ...... . ....... . .......... . ...... . ................. . .......
Engine Sprocket Removal ................. . ............. . ..... . ...... ....... .
Engine Sprocket Installation Notes ............... .. .................... ..
Rear Sprocket Removal .......... . .. . ...... .. . .. .... .. .. . .. .. .. . .. .. .. .. .. . .. .
Rear Sprocket Installation Notes ......... ... " ................... . " .... ..
Sprocket Wear Inspection
Sprocket Warp Inspection .............. .. . .. . ... .. . .... . ... .. .. ...... ..
9-2
9-3
9-3
9-4
9-4
9-4
9- 5
9- 5
9-5
9-6
9-6
9-6
9-7
9-7
9-7
9-7
9-7
9-7
9-8
m
92 FINAL DRIVE
Exploded View
/1
__ - - 500

-- I
---
I . _
I Ii) I,) --
I ,...... .....
("
I
I
I
I ......... ....- I
L.-....... .... ...... .... I
_- I ____ KX125
- I
--
--
I
..J
I _-
1-- --
T1 : 29 N-m (3.0 kg-m. 22,0 ft-Ibl
T2: 98 N-m (10 kg-m. 72 ft-Ibl
FINAL DRIVE 9-3
Specifications
Drive Chain:
Make Daido - --
Type 0 .1.0 520 OS-5 ---
Length: KX125 112link ---
KX250, KX500 114 link ---
Chain slack 50-60 mm less than 50mm, or
more than 65mm
20-link length 317. 5 mm 323 mm
Sprockets:
Engine sprocket diameter KX125 50.98- 51 . 18mm/ 12T 50. 7 mm
KX250,500 60.99- 61. 19mm/ 14T 60. 7 mm
Rear sprocket diameter 227.43- 227. 93mm/ 47T 227. 1 mm
Rear sprocket warp Under 0.4 mm 0 . 5 mm
Special Tools
Bearing Driver Set : 57001 - ' 129
9-4 FINAL DRIVE
. . ...... ................... ... ... .. ... . .. ... ... .. ... .... .... ...
Drive Chain
Drive Chain Slack Inspection
- Support the motorcycle on its side stand.
- Check the wheel alignment (see Wheel Alignment
Jnspectionl and adjust it if necessary (see Wheel
Alignment Adjustment).
NOTE
o Clean the drive chain if it is dirty, and lubricate it if
it appears dry .
Rotate the rear wheel to find the positioo where the
chain is tightest
Measure the vertical movement as shown.
*If the drive chain slack exceeds the standard, adjust
;l
o.tv. Chain Slack Inspoc1ion
1. Engine Sprocket 3. Rear Sprocket
2. Chain Vertical Movement (Slack)
Drive Chain Slack
Standard: 50-60 mm
Drive Chain Slack Adjustment
-loosen the left and right chain adjuster locknuts.
- Loosen the axle nul
A. Axle Nut D. Marks
B. Adjusting Bolt E. Notch
C. Locknut
* If the chain is too tight. back out the left and right
chain adjusting nuts or bolts evenly, and kick the
wheel forward until the chain is too loose.
* If the chain is too loose, turn both chain adjusting
nuts or bolts evenly until the drive chain has the cor
rect amount of slack. To keep the chain and wheel
properly aligned, the notch on the left chain adjuster
should align with the same swing arm mark as the
right chain adjuster notch.
- Check the wheel alignment.
- Tighten both chain adjuster locknuts securely.
- Tighten the axle nut to the specified torque.
Tightening Torque
98 N-m (10 kg-m, 72 fNb)
- Rotate the wheel, measure the chain slack again
at the tightest position, and readjust if necessary.
I WARNING'
ott the axle nut Is not securely tightened. an un-
safe riding condhion may result.
- Check the rear brake for weak braking power, and
brake drag (see the Brakes chapter).
NOTE
oJn wet and muddy cond;rions. mud sticks to the
chain and sprockets resulting in an overly tight
chain. and the chain may break. To prevent this.
adjust the chain to 55 - 65 mm of slack whenever
necessary.
- Check that the notch on the left chain adjuster aligns
with the same swing arm mark as the right chain
adjuster.
A. Marks B. Notches
NOTE
oWheel alignment can also be checked using the
straightedge or string method.
I WARNING'
oMisaignment of the wheel wiN resutt in abnormal
wear, and may resuft in an unsafe riding condition.
Wheel Alignment Adjustment
This procedure is the same as Drive Chain Slack
Adjustment
Drive Chain Wear Inspection
-Rotate the rear wheel to inspect the drive chain for
damaged roUers, and loose pins and links.
Drive Chain Wear Inspection
FINAL ORIVE 9-5
* If there is any irregularity. replace the drive chain.
* Lubricate the drive chain if it appears dry.
- Stretch the chain taut by hanging a 10 kg (20 Ib)
weight on the chain.
- Measure the length of 20 links on the straight part of
the chain from the pin center of the 1st pin to the
pin center of the 21st pin. Since the chain may wear
unevenly. take measurements at several places.
* If any measurements exceed the service limit, re-
place the chain. Also, replace the front and rear
sprockets when the drive chain is replaced.
A. Weight B. Measure
Drive Chain 20-Unk Length
Standard:
Service Umit:
317.5 mm
323 mm
I WARNING'
0" the drive chain wear exceeds the S8t'Vice Hmit.
repface the chain or an unsafe riding conditJon
may result. A chain that breaks Of' jumps off the
sprockets could snag on the engine sprocket or
lock the rear wl'Mtm. severely damaging the motor-
cycle and causing it to go out of control.
Bushi ng
Roller
Pin Link Roller Link
1st 2nd 3rd 4th 20th 21st
~ k E Measure this length ~ > > l 1
9-6 FINAL DRIVE
Drive Cha in
Make Daido
Type 0.1. 0 52005-5
links: KX125 112
KX250 114
KX500 114
Drive Chain LubriC8tion
- If the cnain appears especially dirty, it should be
cleaned before lubrication with high flash-point sol-
vent
- Apply oil to the si des of the rollers so that oil
wi ll penetrate to the rollers and bushings.
- Wipe off any excess oil.
Drive Chain Lubrication
_ , Applyoil.
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.
_Remove the drive chain from the chassis.
Drive Chain Installation Notes
- Fit the drive chain back onto the sprockets with the
ends at the rear sprocket
- Install the master link from the frame side.
-I nstall the clip so that the closed end of the "U"
pointed in the direction of chain rotation.
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).
Sprocket
Engine Sprocket Removal
Engine Sprocket Cover
Drive Chain(free of engine sprocket)
- Remove the circlip, and pull off the engine sprocket.
Engine Sprocket Installation Notes
A. Engine Sprocket
B. Circlip
- For KX125; instal l the sprocket so that the cham-
fered side faces inside.
A. Chamfered Side
Rear Sprocket Removal
- Remove the rear wheel (see Rear Wheel Removal in
the WheelsfTires chapter).

000 not lay the wheel on the ground with the disc
PIece blocks under the wheel so that the disc
does not touch the ground.
FINAL DRIVE 9-7
- Unscrew the rear sprocket bolts, and remove the
rear sprocket
Rear Sprocket Installation Notes
- Install the rear sprocket so that the marked side
faces out
-Tighten the rear sprocket bolts to the specified torque.
Tightening Torque
29 N-m 13.0 kg-m. 22.0 h-lb)
A. Rear Sprocket B. Mark
-Visually inspect the front and rear sprocket teeth
for wear and damage.
* If they are wom as illustrated or damaged. replace
the sprocket
'-.
Worn Tooth
(Engine Sprocket)
t
.t
Worn Tooth
(Rear Sprocket)
,
\ ,:
..... "
-.
a
,

Direction of rotation
.-
- Measure the diameter of the sprocket at the base of
the teeth.
* If the sprocket is worn down to leS5 than the
service limit, replace the sprocket
9-8 FINAL DRIVE
Sprocket Oiamete,
(Engine)
10(125
Standard:
Service lImtt :
10(250. 500
Standard:
Service limit:
IR r)
Standard:
Service limit:
50.98-61.18 mm
50.7 mm
60.99- 61 . 19 mm
60.7 mm
227.43-227.93 mm
227.1 mm
NOTE
olf IJ sprocket requires replacement, the chain
is probably worn also. When rep/acing 8
sprocket, inspect the chain.
Sprocket Warp Inspection
Elevate the rear wheel so that it wi ll turn freely,
and set a dial gauge against the rear sprocket near
the teeth as shown. Rotate the rear wheel . The
difference between the nighest and lowest dial
gauge readings is the amount of runout (warp).
* if the runcut exceeds the service limit. replace the
rear sprocket.
, . Dial Gauge
3. Rotate
2. Rear Sprocket
Raar Sprocket Warp
Standard:
Service Limit:
Under 0.4 mm
0 .5 mm
BRAKES 10 1
Brakes
Table of Cont ents
Exploded View .............................. , ............... . .................... ... . 10-2
Speci ficati ons . ...... ....................................... . ........ , ...... ... 10-4
Special Tool .... . ................... . ................................. . ............... . 104
Di sc 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 .......................... , ........... , ....................... ............. ... . 106
Caliper Removal ......... " ............ . ...... ... ............................. . 10 6
Caliper Installation Notes ....... .......................................... . 106
Caliper Disassembly ........................... .. ........................... . 106
Caliper Assembly Notes .... . ....... . ..... . ............... . ........... . .... . 107
Fluid Seal Damage ... .... . ........ . ... .. . ............ . . ....... ...... .... .. . . . 10-7
Dust Seal and Cover Damage .... ............. ......................... .. 107
Piston Cylinder Damage .. . .......... ................. .................... .. 107
Caliper Holder Shaft Wear ......... . ....................... .. ............ .. 107
Brake Pads " .................. . ........... .. .. ...... .. ... .. .. .. .. . ... .... .. .. .. . . .. 10-8
Pad Removal ..................... . .......... . ............................... . .. 10-8
Pad Installation ...... .. ........ .. ............... ............................. ..
Pad Inspection ................................... .. .................. . ....... ..
Master Cylinder .................... , ............................................. .
10-8
1m
10-8
10 8
Front Master Cylinder Removal ..................................... . .. .. 108
Front Master Cylinder Installation Notes ............................ . 10-9
Rear Master Cylinder Removal ....... ................ . ... .. .. . .. .... .... . 10-9
Rear Master Cylinder Inst allation Notes .. ......... . ........... .. . . .. 10-10
Front Master Cylinder Di sassembly ... .......... .......... .. .. .. .. .. .. 10-10
Rear Master Cylinder Disassembly .... . ...... .... . ...... .. .... .. ...... .. 10-10
Master Cylinder Assembly Notes .. . .. . .... ....... .. .... ...... .. .. .... .. 10-11
Master Cylinder Inspection (Visual Inspection) ................... .. 10- 11
Brake Disc ................... , ....... , .. ........................... , .............. .. 1012
Disc Inspection ... .. . . ........................... ,............. . ... ..... . ...... , 0 '2
Brake Fluid ....... .... .. ...... , ....... , .............. ,.,., ................ ....... . ... . 1012
Brake Fluid Requirement ....................... ......... .......... ,........ , 012
Brake Fluid Level Inspection .. . .. ...... .... . ...... .......... .............. 1013
Brake Fluid Change ....... .......... ...... ......... .... ........ .... .......... 10 13
Bleeding the Brake Line ....... .... .. .. .. .. .. .... .. ... .. .... .. .. ... .... ..... 10-14
Brake Hose .. ..... . ......................... . .. ... .. . .... .... ................ . ...... 10- 15
Brake Hose Removal/Installat ion Notes ..... ........... ...... .... ..... 10-15
Brake Hose Inspection ............... ......... .... .......................... 10- 15
~ ~ ~ I ~ ~ ~ ~ ~ : I ~ ~ ... .......... .......................... . ...............
10-2 BRAKES ........ ........ .. .. ........... ...... . .
Front Disc Brake
@
Disc Brake Rear
j---@
" . ~
~ I
[!l
. W fIJfIJ
l..Jr
I
'I
52 in-Ib)
9 N-m (0.6 kg-m. 18.0 ft-Ib)
T1 : ~ N-m 12. 5 kg-rn. 78 In-Ibl
T2: 8 N-m 10.9 kg-m. 18.0 ft-Ib)
T3: ~ N-m 12.5 kg-m. 69 in-Ibl
T4: 78 N-m (0.8 kg-m. 87 in-Ibl
T5: 's N-m 11 .0 kg-m. 78 in-Ibl
T6: 9. (0.9 kg-m.
T7: 8.8 N-m
BRAKES 10-3
104 BRAKES
..................... .... ........... .............. ... ...... ..
Specifications
Disc Brake
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 3.7 mm
, mm
Rear 4 .2 mm
, mm
Brake Discs:
Disc thickness: Front 3.05 - 3.35 mm 2.5 mm
Aear 4.35-4.65 mm 3.8 mm
Di sc runout not more than 0. 12 mm 0 .3 mm
Brake Fluid:
Recommended disc brake fluid:
Grade D.O.T.3 ---
Brand Atlas Extra Heavy Duty -- -
Sheil Super Heavy Duty ---
Texaco Super Heavy Duty ---
Wagner Lockheed Heavy Duty ---
Castrol Girting-Universal ---
Castrol GT ILMAI ---
Castrol Di sc Brake Fluid -- -
Special Tool
Clrcllp Pller.: 57001-143
Disc Brakes
[ WARNING'
oWhen working with the disc brake. observe the
precautions listed betow.
1. Never reuse old 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 boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to e t ~
riorate.
4. Don' t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don' t change the fl uid in the rai n or when a strong
wi nd is blowi ng.
6. Except for the disc pads and discs. use onl y 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 spilled on any part will be
difficult to wash off completely and will eventually
reach 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 oil gets on them.
Clean off any fluid or oil that inadvertently gets
on the pads or disc with a high flash point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be
cleaned sati sfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spill ed fluid should be completely wiped up i m m ~
diaataely.
9. If any of the brake line fittings or the bleed val ve
is opened at any time, the AIR MUST BE BLED
FROM THE BRAKE.
Brake Adiustment:
Brake Lever/ Pedal Free Play/Adjustment
Disc and disc pad wear is automatically compensated
for and has no effect on brake lever/pedal action. So
there are no parts that require adjustment on the
brakes except brake lever play. brake pedal position
and pedal play.
If the brake lever/pedal has a soft or "spongy feel-
ing", check the brake fluid level in the reservoir and
bleed the air from the brake line (see Bleeding the
Brake Line).
BRAKES 10-5
Front Brake Lever Play Adjustment
- Adjust the front brake lever to suit you.
- loosen the adjuster locknut and turn the adjuster
to either side.
- After adjustment tighten the locknut securely.
A. Brake l ever C. locknut
B. Adjuster
Rear Brake Pedal Position Adjustment
-Adjust the rear brake pedal posit ion to sui t you.
- loosen the locknut tum the adjusting bolt, and then
tighten the locknut
-
;
A. locknut B. Adjusting Bolt
10 6 BRAKES
Rear Brake Pedal Play Adj ustment
- Adjust the rear brake pedal pl ay to suit you.
- Loosen the adjuster locknut and turn t he adjuster on
t he rear master cyl inder.
- After adj ustment, t ighten t he locknut securely.
A. Adj uster C. Brake Pedal
B. Rear Master Cylinder D. l ocknut
Caliper:
Caliper Removal
-loosen the banjo bolt at the brake hose lower end,
a nd tighten it loosely.
- Unscrew the mounti ng bolts, and remove t he caliper
f rom t he disc.
- Unscrew the banjo bolt and remove the brake hose
from the caliper (see Brake Hose Removai/installa
tion),
oThere is a flat washer on each side of the hose fitting.
If the cali per is to be disassembled after removal
and if compressed ai r is not available, remove
the piston using the foll owi ng steps before dis-
connecting the brake hose from the caliper,
oRemove the pads.
oPump the brake lever or pedal to remove the cali-
per piston.
NOTE
oJmmedi,teJy wipe up any brake fluid that spiIJs.
A. Front Caliper
D. Brake Hose
B. Caliper Mounting Bolts E. Banjo Bolt
C. Brake Disc
A. Caliper Cover
B. Mounting Bolts
C. Rear Caliper
D. Caliper Mounting Bolts
E. Brake Disc
F. Brake Hose
C. Banjo Bolt
Caliper Installation Notes
- Insta ll at ion is the reverse of removal.
-Tighten the caliper mounting bolts to the specified
torque,
TIghtening Torque:
25 N-m 12.5 kg-m, 18 ft-lb)
- Use a new flat washer on each side of the brake hose
fitting, and tighten the banjO bolt to the specified
torque,
TlQhtening Torque:
25 N-m f2.5 kg-m. 18
- Check the brake fluid level in the reservoi r, and bleed
the brake line (see Bleeding the Brake
- Check the brake for weak braking paoNer, brake drag.
and fl uid leakage by operating the brake lever/pedal.
Caliper Disassembly
- Remove the pads, spring, and dust seal (see Pad

- Using compressed air, remove the piston.
OCover the caliper opening with a clean, heavy cloth.
oRemove the piston by lightly applyi ng compressed air
to where the brake line fits into the caliper.
I WARNING I
oTo avoid serious injury. never place your fingers or
inside the caliper opening. If you appty com-
pressed air into the caliper. the piston may crush
your hand or fingers.
A. Apply compressed air. B. Cloth
NOTE
olf the caliper is to be disassembled after removal
and compressed air is not available, remove the
piston using the following three steps before
disconnecting the brake hose from the caliper.
oPrepare a suitable dished container for brake fluid,
and perform the work above it.
oRemove the pads, spring, and dust seal (see Pad
Removal).
oPump the brake lever or pedal to remove the
caliper piston.
o/mmediately wipe up any brake fluid that spills.
It ruins painted or plated surfaces.
Caliper Assembly Notes
- App[y brake fluid to the outside of the piston and the
fluid seal, and push the piston into the cylinder by
hand. Take care that neither the cylinder nor the
piston skirt get scratched.
- [nstall the dust seal around the piston. Check that
dust seal is properly fitted into the grooves in the
piston and caliper.
- Apply a thin coat of PBC (Poly Butyl Cuprysillgrease
to the caliper holder shafts and holder holes (PBC
is a special high temperature, water-resistant grease).
- Install the anti-rattle spring in the calipers as shown.
A. Anti-rattle Spring
BRAKES 10-7
- Install the pads (see Pad Installation).
Fluid Seal Damage
The fluid seal around the piston maintains the
proper padfdisc clearance. If this seal is not in good
condition, pad wear wil l increase, and constant pad
drag on the disc will raise brake and brake fluid temper
ature.
Cal per
1. Caliper
2. Piston
3. Fluid Seal
4. Dust Seal
Replace the fluid seals under any of the following
conditions: (a) fluid leakage around the pad; (b) brakes
overheat; (c) there is a large difference in left and
right pad wear; (d) the seal is stuck to the piston. If
the fluid seal is replaced. replace the dust seal as well.
Also, replace all seals every other time the pads are
changed.
Dust Seal and Cover Damage
-Check that the dust seals and covers are not cracked,
wom, swollen, or otherwise damaged.
* If they show any damage, replace them.
Piston Cylinder Damage
- Visually inspect the piston and cylinder surfaces.
* Replace the cylinder and piston if they are badly
scored or rusty.
Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper
holder shafts. If the body does not slide smoothly,
one pad will wear more than the other, pad wear will
increase, and constant drag on the disc will raise
brake and brake fluid temperature.
- Check to see if the caliper holder shafts are not badly
worn or stepped, or the rubber friction boot is not
damaged.
* If the shafts or rubber fri ction boot are damaged,
replace the shafts. rubber friction boot, and the
caliper holder.
10B BRAKES
Brake Peds:
Pad Removal
- Remove the caliper from the disc. and take out the
piston side pad from the caliper holder .
Push the caliper holder toward the piston, and then
remove the pad from the caliper holder shaft.
A. Pads C. Holder Shafts
B. Caliper Holder
Pad Installation
Push the caliper piston in by hand as far as it will go.
Install the antirattle spring.
-I nstall the piston side pad first. and then install the
remaining pad.
I WARNING.
000 not attempt to drive the motorcycle until a
full brake lever or pedal I. obtained by pumping
the brake lavar or pedal until the pads are against
the disc. The brake will not function on the first
application of the levar or pedal If this I, not done.
Pad Inspection
Check the lining thickness and condition of the pads
in each caliper.
* If either pad is damaged, replace both pads in the
caliper as a set.
* If the lining thickness of either pad is less than the
service limit, replace both pads in the caliper as a
set.
lini ng Thickness Measurement
A. lining Thickness B. Service limit
Pad lining Thk:kness Imml
Front Rear
Standard 3.7 4.2
Service limit 1 1
Master Cylinder:
oBrake fluid quickly ruins painted or plated sur-
faces; any spilled fluid should be completely
wiped up immediately.
Front Master Cylinder Remo val
- Remove the banjo bolt to disconnect the upper brake
hose from the master cylinder. There is a flat washer
on each si de of the hose fitting.
A. Banjo Bolt C. Reservoi r
B. Master Cylinder
- When removing the brake hose, temporarily secure
the end of the brake hose to some high place to
keep fluid loss to a minimum.
- Unscrew the damp bolts, and take off the master
cylinder as an assembly with the reservoir and brake
lever.
A. Clamp Bolts
Front Master Cylinder Insta/Jation Notes
- Tighten the upper clamp bolt first and then tighten
the lower clamp bolt to the specif ied torque. There
will be a gap at the lower part of the clamp after
tightening.
Tightening Torque
8.8 N-m (0.9 kg-m. 78 in-lb)
BRAKES 10-9
A. Arrow Mark
- Use a new flat washer on each side of the brake
hose fitting, and tighten the banjo bolt to the sped-
fied torque.
Tightening Torque:
25 N-m 12.5 kg-m. 18 ft-lb)
- Bleed the brake line after master cylinder installation
(see Bleeding the Brake line).
- Check the brake for weak braking power, brake drag,
and fluid leakage.
Rear Master Cylinder Removal
- 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. Cotter Pin
B. Joint Pin
C. Master Cylinder Mounting Bolts
D. Banjo Bolt
E. Master Cylinder
10-10 BRAKES
the end of the brake hose to some high place to
keep fluid loss to a minimum.
- Unscrew the master cylinder mounting bolts, and
remove the master cylinder with the reservoir .
Unscrew t he reservoi r cap (the diaphragm comes
off with the reservoir cap) and pour the brake fluid
into a container.
- Remove the reservoir and its hose from the master
cylinder.
Reer Master Cylinder Instal/Brion Notes
- Tighten the master cyli nder mounting bolts securely,
- Use a new flat washer on each side of the brake
hose fitting. and tighten the banjo bolts to the
specified torque.
Tlghtonlng T",-
25 N-m 12.5 kgm. 18 It-Ibl
- Tighten the reservoir mounting boh securely,
- Bleed the brake line after master cylinder installation
-Check the brake for weak brakins power, brake drag.
and fluid leakage.
- Check the brake pedal position.
Front Master Cylinder Disassembly
- Remove the front master cylinder (see Front Master
Cylinder Removal)
- Remove the reservoir cap and diaphragm, and pour
the brake fluid into a container.
- Unscrew the locknut and pivot bolt. and remove the
brake lever.
- Push the dust cover out of place, and using circlip
pliers (specia[ tool: 57OO1-143l remove the cirdip.
- Remove the washer, and pull out the piston,
secondary cup, primary cup, and retum spring.
o[)o not remove the secondary cup from the piston
since removal wfI damage ft .
Front Mast .. CyIInde<

2. Circlip
3. Washer
4. Piston
5. Secondary
Cup
6. Primary Cup
7. Return Spring
8. Reservoir
Rear Master Cylinder Disassembly
- Remove the rear master cylinder (see Rear Master
Cylinder
- Slide the dust cover on the push rod out of place. and
using ci rclip pliers (specia[ tool: 57001-1431 remove
the cirdip.
- Pullout the push rod with the piston stop.
- Take off the piston, secondary cup, primary cup, and
return spring.
000 not remove the MCOndary cup from the piston
oInce """",,01 wlI __ k.
- Remove the ci rclip, and take off the connector
and packing.
,
1. Push Rod
2. Dust Cover
3. Piston Stop
4. Circlip
5. Piston
6. Secondary Cup
7. Primary Cup
8. Return Spring
9. Master Cylinder
10. Packing
11 . Cirdip
12. Connector
Master Cylinder Assembly Notes
- Assembly is the reverse of disassembl y.
- Take care not to damage the inner surface of the
cylinder, or the piston.
- Clean all parts with brake fluid or alcohol, and apply
brake fluid to the inner surface of the cylinder before
assembly.
- Tighten the brake lever pivot bolt locknut securely.
Master Cylinder Inspection
IVisual 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 wom, 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
assembly should be replaced to renew the cup.
- Check the dust covers for damage.
* If they are damaged, replace them.
- Check that the relief and supply ports are not
plugged.
* If the small relief port becomes plugged, the brake
pads will drag on the disc. Blow the ports clean
with compressed air.
- Check the piston return springs for any damage.
* If a spring is damaged, replace it
- Check the packing in the rear master cylinder for
damage.
* If a packing is damaged, replace it
Front and Rear Master CytInder
1. Reservoir
2. Diaphragm
3. Relief Port
4. Suppl y Port
5. Cylinder
6. Return Spring
7. Primary Cup
8. Piston
9. Secondary Cup
10. Washer
'1. Orclip
12. Dust Cover
13. Brake lever
14. Push Rod
BRAKES '0-"
'0-'2 BRAKES
Brake Disc:
Disc Inspection
Visually inspect the disc.
* If it is scratched or damaged, replace the disc .
l\1easure the thickness of each disc at the lX>int where
it has worn the most
* Replace the disc if it has worn past the service l imit.
1. Disc
2. Measuring Area
DIoc l1-kI<nou
Standard: Front: 2.86 - 3. ' 5 mm
Rear: 4.36 - 4.65 mm
Front: 2.5 mm
near; 3.8 mm
Place a stand or block under the motorcycle so that
the front/rear wheel is raised off the ground.
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-
ference between the highest and lowest dial readings
is the amount of runoul
* If disc runout exceeds the service limit, replace the
disc.
Disc Runout Measurement
1. Disc
2. Measuring Area
Disc Runout
Standard:
Service Umn:
Brake Fluid:
under 0.12 mm
0.3 mm
Brake Fluid Requirement
Recommended fluids are given in the table below.
If none of the recommended brake flu ids are avail-
able. use ext ra heavy-duty brake fluid onl y from a
container marked D.O.T.3.
Recommended Disc Brake Fluid
Grade D.C.T.3.
Brand Atlas Extra Heavy Duty
Sheel Super Heavy Duty
Texaco Super Heavy Duty
Wagner Lockheed Heavy
Duty
Castrol Giriing-Universal
Castrol GT ILMAI
Castrol Disc Brake FhoJid
Brake Fluid Level Inspection
Inspect the brake fluid level in the front and rear
brake fluid reservoirs period ica lly.
- Check the brake fluid level in the reservoir.
NOTE
o Hold the reservoir horizontal when checking
brake fluid level.
* The front and rear reservoirs must be kept more
than half fu ll with brake flu id. If the amount of
brake fl uid is insufficient, add brake fluid.
Front Brake Flukt Reservoi r
A. Front Reservoir
Rear Brake Fluid Resarvoir
A. Rear Reservoir
BRAKES 10-13
Brake Fluid Change
Change the brake fluid periodically. The brake fluid
should also be changed if it becomes contaminated
wi th dirt or water.
Changing Brake Auld:
- level the master cylinder brake fluid reservoir.
- Remove the rubber cap on the bleed valve.
- 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 opent
- Pump the brake lever or pedal unti l all the fluid is
drained from the line.
- Close the bleed valve.
- Remove the reservoir cap.
- Fill the reservoir with fresh specified brake fluid.
WARNING'
000 not mix two brands of fluid. Change the brake
fluid in the brake line COfl"\IMtety If the brake ftuid
must be refiled but the type and brand of the
brake fk*t that is already in the reservoir are
unknown.
- Install the reservoir cap.
- Open the bleed valve, apply the brake with the brake
lever or pedal.
-Close the valve with the 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
ORep/Bnish the fluid in the f8sefVOir 85 often 85
necessary to keep it from running completely out.
- Bleed the air from the lines (see Bleeding the Brake
line).
10-14 BRAKES
Filling up the Brake line
, . Open the bleed valve.
2. Apply the brake and hold it.
3. Close the bleed valve with the brake held applied.
4. Then quickly release the brake.
Bleeding the BrBke Line
The brake fluid has a very low compression coeffj..
cient so that almost all movement of the brake lever
or pedal is transmitted directly to the caliper for brak-
ing action. Air, however, is easily compressed. When
air enters the brake lines, brake lever or pedal move-
ment will be partially used in compressing the air.
This will make the lever or pedal 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 fitti ng has
been loosened for any reason.
_Remove the reservoi r cap, and check that there is
plenty of flu id in the reservoir.
NOTE
oThe fluid level must be checked several times
dunng the bleeding opef8tion and replenished as
necessary.
olf the fluid in thB reservoir fUns completely out
any time during bleeding, the bleeding operation
must be done OV8f again from thB beginning since
air wiN have entered the line.
- With the reservior cap off, slowly pump the brake
lever or pedal several times until no air bubbles can
be seen rising up through the fluid from the holes
at the bottom of the reservoir. This bleeds the air from
the master cylinder end of the line.
- 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 ()( pedal a few times until it
becomes hard and then, holding the lever or pedal
squeezed, Quickly open (turn countercl ockwise) 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 T ......
8N-m (0.8 kg-m. 69 ...,)
- Check that the brake fluid is filled to the upper level
line marked in the reservoir (with the master cylinder
held level).
- After bleeding is done, check the brake for weak
braking power, brake drag. and fluid leakage.
Baudlng the Brake lila
1. Hold the brake applied.
2. Quickly open and close the bleed valve with the
brake held applied.
3. Release the brake.
Brake Hose:
Brake Hose RemovaVlnstallation Notes
- When removi ng the brake hose, take care not to
spill the brake fluid on the frame or other painted
parts.
the end of the brake hose to some high place to keep
fluid loss to a minimum.
oBrake fluid quk:Idy ruins painted or p&ated surfaces;
any spiled fluid should be comp!etety wiped up
immediately.
- There is a flat washer on each side of the brake hose
fitting. Replace them with new ones during installation.
- When installing the hoses, avoid sharp bending. kink-
ing. flattening or twisting. and route the hoses accord-
ing to the Hose Rout ing section in the General
Information chapter.
-Tighten the banjo bolts at the hose fittings to the
specified torque.
Tightening Torque:
26N-m 12.5 kg-m. 18 fHbl
-Bleed the brake line after installing the brake hose
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.
BRAKES 10-15
SUSPENSION ,,- ,
Suspension
Table of Contents
Exploded View ............. _ .............................................. ....... ...... 11-2
Specifications .............. _.......... .. .............. ..... . . .................... 11-3
Special Tools ......................................... , ..... . .......................... 11 -4
Front Fork ... ... .. .... .. .. ............................... , ...................... , ... , .... 11 -5
Front Fork Adjustment .................... " .................... . ........... ,. ' 11-5
Fork Oil Change ... ................................ " ... ,_,............ ......... 11-7
Front Fork Removal ....................... ,_, ,_. " ..... ...... _,_ ......... _,_ ,_ ... 11-8
Front Fork Installation Notes ......... ......... ....... ..... ................ 11 8
Front Fork Disassembly .. ...... ....... .......... ............ .. ....... ........ 1 1-9
Front Fork Assembly Notes ............ .......... ... ....... ...... .... ..... 1 11 1
Inner Tube Inspection ................ .. ... ... ........ ... .. ...... ............ 11' 2
Guide Bush Inspection ..................... . .. .. .... .... . ................... 1 1 - 12
Oil Seal and Outer Tube Seal Inspect ion .... ........... .. ... .. .. .... . 1' ' 2
Spring Tension . ... ............... .. .... .......... ...... .. . .. .. ..... .. .. .. .. ... 1' - 12
Rear Suspension (Uni trak) ........... ....... ........... .. ........... ....... .. .... 11 - 13
Rear Shock Absorber .... ................ ....................................... 11 - 13
Shock Damping Adjustment .... ..... ............ .... .......... ..... ...... 1 1- 13
Rear Shock Absorber Removal .. .. .. . .... ....... ..................... .... 1 1 - 15
Rear Shock Absorber Installation Notes ........ ....... ...... ......... 1 1-16
Rear Shock Absorber Spring Replacement ..... ...................... 1 1 - 16
Rear Shock Absorber Disassembly . ... .................. ..... ........ .. 1 1- 17
III
Swing Arm ............. .......... . ..... . .. . . . ......... ..... . . .......... . ......... . ... , 1-20
Swing Arm Removal ........................... ... .. . ... .... ... .. . .. .. .. . .. . ... 1 1-20
Swing Arm Installation Notes .............................. . ............... 11-21
Tierod, Rocker Arm . . ................................. .. .................. .. . ... - 11-21
Tie rod Removal ... ... ...... . .. . ............ .. .................................. 11-21
Ti e-rod Installation Notes ................. ... . .. ... . ... ................. .. ... 11 -2 1
Rocker Arm Removal ......................................... ............ . .. .. 1121
Rocker Arm Installation Notes ...... . ...................................... 11 -22
Uni-trak Maintenance .................................. .. .. .... ......... . .... .. .... 11-22
Sleeve . .. .......... ..... .............................................................. 1'-22
Rocker Arm .... . .. .. ... . ........................................................... 11 -23
Mount ing Bolt Bend ................................ .......................... 11 -23
11-2 SUSPENSION
... .... . .. .. . .. .. ....... .. . .. .... . ... . .
x ~ l o d e d View
.... .. . .. ......... .. .. .. ... . .. ...................... .. .. ... . .

T1: 20 N m 12.0 kg m. 14. 5 ft-Ibl
T2: 54 N-m 15.5 kg-m. 40 h-Ibl
T3: 78 N-m (8.0 kg-m. 58 ft-Ib)
T4: 81 N' m (8. 3 kg-m. 60 ft-Ibl
T6: 34 Nm (3. 5 kg-m. 25 ft-Ib)
SUSPENSION 11-3
Specifications
Front Fork:
Air pressure Atmospheric pressure (Maximum air pres
sure) 40kPa (0.4
kg/cm
2
, Spsi)
Oil viscosity: SAE 5W ---
Oil capacity: KX 125 535 4mL ---
10(250 535 4 mL ---
10(500 597 4 mL ---
(adjustable range)
Oil level: KX125 130 2mm 100 - 160 mm
( full.Y compressed, ) KX250 130 2mm 100 - 160 mm
spring removed KX500 120 2mm 90-15Omm
Compression Damping Adjustment Adjuster turned fully 16 turns
counterclockwise (clockwise)
Fork. spring free length:
10(125, 250 548 mm 537 mm
10(500 553 mm 542 mm
Rear Suspension:
Rear Shock Absorber:
Rebound damping: Adjuster turned fully counterclockwise 16 tums{clockwise)
Spring preload:
adjusting nut position from the
center of the upper mounting
hole
10(125 112 mm 104 - 124 mm
10(250, 500 111 mm 104 - 124 mm
Gas Reservoir: (adjustable range)
Compression damping: Adjuster turned fully counterclockwise 16 tums/clockwise)
Gas pressure: 1200 kPa (12 kg/em' , 170 psi) 1000- 1500 kPa
(10-15kg!em' ,
142-213 psi)
11 -4 SUSPENSION
Special Tools
Front Fork Cylinder Holder: 5700' - '245
Front Fork Oil Seal Driver ; 57001-1219
Front Fork Outer Tube Weight: 5700, -'218
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 fo ll owing methods.
Basically, there are five adjustment you can make
to the front fork .
oAi r pressure adjustment -Air pressure acts as a
progressive spri ng 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 ai r pressure for
additional springing. Your KX forks are designed to
work without adding any ai r, but if you decide that
you need additional air pressure, go no higher
than 40 kPa (0.4 kg/cm
1
, 6 psi).
C<:ompression damping adjustment-This adjustment
affects how quickly the fork compresses. The fork
compression damping adjuster has 16 clicks. The
seated position (full counterclockwise until the adjuster
stops) is full foOft. From that point, 8 clicks clockwise
is the standard setting, and 16 clicks (full clockwise
until the adjuster stops) is full hard.
COil level adjustment-The effects of higher or lower
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
(less oil) will make the fork rebound more slowl y.
aFork springs -Optional springs are available that
are softer and stiffer than standard.
oFork clamp position-Steering qualities are greatly
affected by the fork clamp position (If amount of
the inner tube projecting above the steering stem
head). When the fork tube height is smaller, the
front end become lighter due to the change in
weight bias. Also, it tends to understeer in turns
and wash our'". When the height is greater, the
results are opposite.
Air Pressure Adjustment
_Use a jack under the engine or other suitable means to
lift the front of the motorcycle.
_Remove the air valve cap on the top of the front fork,
and check the air pressure. Standard air pressure is
atmospheric pressure.
SUSPENSION 11 -5
NOTE
000 not use the side stand when the air pressure
is checked.
oCheck the air pressure when the front forks are
cold.
* If atmospheric pressure is insufficient. add air using
a tire pump until the desired pressure is reached.
Make sure that the pressure is equal in both forks.
Maximum air pressure
40 kPa 10.4 kg/cm
2
, 6 psi)
Olnject air little by little so that air pressure does
not rise rapidly. Air pressure exceeding 250 kPa
(2. 5 kg/cm
2
, 36 psil may damage the 011 seal.
WARNING I
oUse only air or nitrogen gas.
0 00 not incinerate the front fork.
Compression Damping Adjustment
- Clean the bottom of the outer tubes.
- Remove the caps on the bottom of the outer tubes.
- To adjust compression damping. turn the adjuster on
the front fork cylinder valve with the blade of a
screwdriver until you feel a dick. Adjust the com-
pression damping to suit your preference under special
condition.
A. Adjuster
11-6 SUSPENSION
Softer E
o 2
i
Standard ..,. Harder
4 6 8 10 12 14 16
Number of turns clockwise
usable r8nge 16 clicks
Seated position adjuster turned fully
counterclockwise
oThe left and right fork lega must have the same
shock damping.
-Put the caps into the bottom of the outer tubes .
Oil Level Adjustment
- Use a jack under the engine or other suitable
means to lift the front of the motorcycle.
-Remove the air valve caps and release any air
pressure.
I WARNING'
OWhen disassembling the front fork, first release
the air pressure from the fork. Failure to first
release the air may cause injury.
-Remove the handlebar clamp bolts and take out
the handlebar.
-Remove the top bolts from the top of the fork tubes.
- Slowly compress the front forks about 100 mm.
-Hold the push rod steady using the spanner, and
loosen the top bolts.
A. Top Bolt B. Push Rod
-Remove the top bolts from the top of the push
rod, and pull out the spring seat, spacer, spring
seat and spring. Check the a'ring of the top bolts
for damage. If necessary, replace them.
I
A. Top Bolt D. Spacer
B. aRing E. Spring
c. Spring Seat
-Take out the jack or other suitable means under the
engine, and slO''lly compress the front forks all the
way.
-In this position, insert a rod down into the tube, and
measure the distance from the top of the inner tube
to the oi l level.
Standard Oil Lev"':
KX125: 130

2mm
KX260: 130

2mm
KX500: 120

2 mm
Adjustable Range:
KX125: 100 - 160 mm
KX25O: 100 - 160 mm
KX500: 90- 150 mm
A. Rod
- Adjust the oil level as required within the adjustable
range using one of the foll owing oils.
Recommended Oil
SAE 5W
Fork Spring
Different fork springs are available to achieve ~ i t b l e
front fork action in accordance wit h the rider's weight
and track condition.
eHarder springs make the fork stiffer, and rebound
action quicker.
eSofter springs make the fork softer, and rebound aciton
slower.
Fork Clamp Position
Steering qualities are greatly affected by the
fork clamp po,sition (the amount of the inner tube
projecting above the steering stem head). When
the fork tube height is small er, the front end be-
comes lighter due to change in weight bias. Also,
it tends to understeer in turns and " wash out".
When the height is greater, the results are opposite.
Be sure the front tire doesn' t rub the fender
when the fork tubes compress full y. Make this
adjustment in 5 mm increments.
oThe inner tubes, both right and left. should be
adjusted evenlv.
A. Tube Height
Fork Oil Change
- Remove the air val ve caps and release any air pres-
sure.
I WARNING .
oWhen disassembling. checking the oil level . and
changing the oil of the front fork, first release the
air from the fork. Failure to first release the air may
cause injury.
SUSPENSION 117
- Remove the drain screw from the lower end of
the outer tube on each side.
A. Drain Screw
e<:ompress the front fork a few times to pump out the
oil.
e Place a jack or other suitable means under the engine 5(1
that the front wheel is rised off the ground.
eApply a nonpermanent locking agent to the drain
screws and install them.
- Remove the handlebar damp bolts and take out
the handlebar.
- Remove the top bolts from the top of the fork tubes.
- Slowly compress the front forks about 100 mm.
- Hold the push rod steady using the spanner, and
loosen the top bolts.
- Remove the top bolts from the top of the push rod,
and pull out the spring seat, spacer, spring seat
and spring. Check the ().ring of the top bolts for
damage. If necessary, replace them.
" 8 SUSPENSION
A. Top Bolt
B. ORing
C. Spring Seat
D. Spacer
E. Spring
F. Push Rod
C. Upper Hole
H. Side Hole
- Pour in the type and amount of fork oi l specif ied.
Recommended oil
KAYABA 01 or SAE 5W
Front Fork Oil Capacity:
KX125:
KX250;
KX500;
535 ::t; 4 ml
635 :t: 4 mL
597 ::l:: 4 mL
Pump the fork slowly several times to expel the
air from upper and lower chambers.
_ In order to expel all the air from the cyli nder,
carry out the foll owing steps:
OWith the fork fully compressed pull up the push
rod slowl y and push it in slowly for a distance
of about 50 mm. then quickly through to the
bottom of its stroke with one conti nuous moti on.
Repeat thi s procedure until all the ai r inside is
expell ed (that is, until the push rod moves up
and down smoothl y wit hout sticki ng).
o Be SUfe to point the hole. In the push rod away
from you to prevent 011 from .plashlng your
body.
- Check the oil level.
o With the fork fully compressed, insert /II tape measure
Of rod into the inner tube, and measure the distance
from the top of the inner tube to the oil.
* If the oil is above or below tile specified level. remO\lf!
or add oil and recheck the oil level.
Fork 01 L V ~ Measunnent
Front Fork Oil L V ~ (Standard)
KX125: 130 2 mm
130 2 mm
120 2 mm
-I nstall the parts removed.
Front Fork Removal
1. Oil Level
- Remove the caliper from the fork leg to be removed,
and rest the caliper on some kind of stand so that
it doesn' t dangle.
- Remove the front wheel (see Front Wheel Removal
in the Wheels/Tires chapter).
-Loosen the upper and lower fork clamp bolts .
8
A. Upper Fork Clamp Bolts
B. LO'Nef Fork Clamp Bolts
- With a twisting motion, work the fork leg down
and out
Front Fork Installation Notes
-If the fork leg 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 damp bolts to the speci ..
fied torque.
Tightening Torque
20N-m (2.0 kg-m. 14.6 ft .. IbJ
- Mount the axle clamps, and tighten the clamp
nuts, first tighten the upper clamp nuts and then
the lower clamp nuts to the specified torque. The
arrow mark on the axle clamp must point upwards.
A. Arrow Mark
B. Upper Clamp Nuts
C. lower Clamp Nuts
Tightening Torque
9.3 N-m (0.95 kg-m, 82 in-ib)
-Tighten the caliper mounting bolts to the speci
fied torque.
Tightening Torque
25N-m (2.5 kg-m, 18 ft -Ibl
- Check front brake operation after installation.
Front Fork Disassembly
_Remove the front fork leg.
_Remove the dust seal from the outer tube.
_Release the air and loosen the top bolt each fork
wbe.
I WARNING'
oWhen disassembling, checking the oil level , and
changing the oil of the front fork, first release the
air from the fork . Failure to fitst release the air may
cause injury.
_Remove the top bolt from the top of the fork tubes.
-Slowly compress the front forks about 100 mm.
_Hold the push rod steady using the spanner, and loosen
the top bolts.
SUSPENSION 11-9
-Remove the top bolts from the top of the push
rod, and pullout the spring seat, spacer, spri ng
seat. and spring. Check the O-ring of the top bolts
for damage. If necessary, replace them.
A
A. Top 80lt D. Spacer
B. O-Ring E. Spring
C. Spring Seat
- Pour the fork oi l into a container.
-Remove the push rod nut from the push rod.
A. Push Rod Nut
11 10 SUSPENSION
ecJCi n the bottom of the outer tube.
- Remove the caps on the bottom of the outer tubes.
eHold the front fork with a vise.
- Stop the cylinder from turning by usi ng the cylinder
holder (special tool). Unscrew the cyli nder va lve
assembly, and take the cylinde r valve assembly and
aasket out of the bottom of the outer tube.
(
1. Cylinder Holder: 57001 -1245
2. Cylinder Unit
3. Cylinder Va lve Assembly
-Remove the cylinder unit and push rod from the
top of t he front fork tube.
B
A
A. Cylinder Unit B. Push Rod
- Separate the inner tube from the outer tube as
follows.
ORemove the retai ning ring f rom the outer tube.

A. Retaining Ring B. Outer Tube
OMount the front fork outer tube weight (special
tool) on the top of the outer tube. by fitting the step
of the weight (special tool) to the top corner of the
outer tube.
oHolding the inner tube by hand in a vertical pos i-
tion, stroke t he outer tube up and down several
times and pull it down. This shock to the fork leg
separtes t he outer tube from the inner tube.
Front Fork Separation
() -
1. Inner Tube
2. Front Fork Outer Tube Weight : 57001 1 218
3. Outer Tube
4. Stroke
A. Inner Tube D. Washer
B. Outer Tube Seal E. Outer Tube Guide Bush
C. Oil Seal F. Inner Tube Guide Bush
- Remove the cylinder base from the bottom of the
outer tube.
A. Outer Tube B. Cylinder Base
Front Fork Assembly Notes
- Check the O-ring at the top bolt. Replace it with a
new one if damaged.
- Replace the oil seal removed with a new one.
- Replace the guide bushes with new ones.
- Insert the cylinder unit and push rod in the inner
tube.
- Insert the cylinder base in the cylinder unit.
A. Inner Tube C. Cylinder Base
B. Cyl inder Unit D. Push Tod
SUSPENSION 11-11
- Insert the inner tube and cylinder unit as a set into
the outer tube.
* Visually inspect the cylinder valve assembly for
damages, and replace it if necessary.
A. Cylinder Valve Assembly
- Apply a liquid gasket to both sides of the gasket,
and apply a non-permanent locking agent to the
threads of the cylinder valve assembly at the bot-
tom of the outer tube.
_Stop the cylinder from turning by using the cylinder
holder (special tool : 57001-1245). tighten the cylin-
der valve assembly to the specified torque.
Tlghtenlng T otqU8
54 N-m 15.5 kg-m. 40 ft-Ib)
-Install the cap on t he bottom of t he outer tube.
-When replacing the outer tube guide bush with a
new one, hold the used guide bush against the new
one. and tap the used guide bush with the front fork
oil seal driver (special tool) until it stops. The slit
in the bush must face toward the wheeL
Guide Bush Installation
1. Front Fork Oil Seal Driver: 57001-1219
2. Used Guide Bush
3. Slit (face toward the wheel)
4. New Guide Bush
5. Outer Tube
6. Tap
1112 SUSPENSION
- After installing the washer, install the oi l seal by
using the fork oi l seal driver (special tool : 57(X)1
1219,
- Using the fork oil seal dri ver (special tool : 57001
1219), install the dust seal.
.Pour in the type and amount of fork oil specified,
and adjust the oil level (see Fork Oil Change).
-Install the fork spring so that sealed side faces
down.
A. Sealed Side
Inner Tube Inspection
Visually inspect the inner tube, repair any damage.
Nicks or rust damage can sometimes be repaired
by using a wet-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 or replaced.
Temporarily assemble the inner and outer tubes,
and pump them back and forth manually to check
for smooth operation.
olf the inner tube Is badly bent or creased, replace It.
Excessive bending, followed by subsequent
straightening, can weaken the Inner tube.
Guide Bush Inspect;on
Visually inspect the guide bushes, and replace them
if necessary.
A. Guide Bushes
Oil Se81 and Outer Tube Seal Inspection
Inspect the outer tube seal for any signs of de-
terioration or damage.
... Replace them if necessary .
Replace the oil seal with a new one whenever it
has been removed.
A. Oil Seal B. Outer Tube Seal
Spring Tension
Since a spring becomes shorter as it weakens,
check its free length to determine its condition .
... 11 the spring of either fork leg is shorter than the
service limit, it must be replaced. If the length of
a replacement spring and that of the remaining
spring vary greatly. the remaining spri ng should
also be replaced in order to keep the fork legs
balanced for motorcycle stability.
Fork Spring Free Length
Standard: KX125, 250: 548 mm
KX500, 553 mm
Service Limit : KX125,250: 537 mm
KX500: 542 mm
. .. "
. . . . ~ - ~
SUSPENSION 11- 13
Rear Suspension IUni-Trak)
Rear Shock Absorber :
The rear suspension system of this motorcycle is
Uni-trak . It consists of a rear shock absorber. swing
arm, tie rod and rocker arm.
To suit to various riding conditions, the spring
preload of the shock absorber can be adjusted or
the spring can be replaced wi th an optional one.
Also the damping force can be adjusted easi ly so
changing oil viscosity is unnecessary.
Shock Damping Adjustmtmt
Rear Shock Absorber
Rebound Damping Adjustment
To adjust shock rebound dampi ng, turn the re-
bound damping adjuster on the rear shock absorber
lower end with the blade of a screwdriver unti l you
feel a click.
If the damper setting feels too soft or too stiff.
adjust it in accordance with the foll owing table:
Softer ( ) Harder
1 4 7 10 13
t
Number of turns clockwise
usable range-16 clicks
Seated position adjuster turned fully
counterclockwise
16
11- 14 SUSPENSION
A. Rebound Dampi ng Adjuster
B. Mark
Gas Reservoir
To adjust compression damping. turn the compres-
sion damping adjuster on the gas reservoi r with the
blade of a screwdriver until you feel a click.
If the damper setting feels too soft or too stiff ,
adjust it in accordance with the following table.
Softer ..
(Counterclockwise)
1 4 7
I I I
10
I
Harder
(Clockwi se)
13 16
I I
t
Number of t urns clockwise
usable range 16 clickl
Seated positions adjuster turned full y
counterclockwise
A. Compression Damping Adjuster
B. Mark
Gas Pressure Adjustment
The gas pressure in the gas reservoi r can be ad-
justed for different course and loading condi t ions.
The foll owing table shows an example of gas
pressure adjustment. To obtain stable handling or
a suitable riding condition, adjust the gas pressure
for different course and loading conditions as neces-
sary. The standard gas pressure is 1200 kPa (12.0
kg/cm
2
, 170 psi). Ordinaril y, the heavier the total
load becomes, the higher the gas pressure should be
set.
Gas Pressure Adjustment (Adjustable Rangel
Gas Pressure
Setting
kPa (kg/em
2
, psi)
Load Course
1000 110.0, 1421 Soft Light Smooth
! t t t
1500 (15.0, 213) Hard Heavy Rough
To adjust the gas pressure:
Non;
oCheck and adjust the gas pressure when the gas
reservoir is cold (room tempereture) .
- Use a jack 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. Valve Cap
- If standard pressure is insufficient for you, add nitre;
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
ridi ng conditions.
I WARNING'
OUS8 onlv nitrogen gas.
000 not incinerate the gas reservoir.
Spring Preload Adjustment
- Remove the seat, right and left side covers.
-loosen the air cleaner duct clamp screw.
- Remove the silencer.
- Remove the rear frame a nd air cleaner case.
A. Rear Frame B. Ai r Cleaner Case.
Place a study block or support under the frame so
that the rear wheel is ra ised off the ground.
- Usi ng the hook wrenches (special tools), loosen the
locknut and turn the adjusting nut as required. Turn-
ing the adjusti ng nut down makes the spring preload
stronger.
A. Adjusting nut C. Hook Wrench: 57001-1101
B. locknut
- Standard spring preload is 612 N (62.4 kg, 138 Ib)
{KX500: 635 N (64.8 kg, 143 Ib . The adjusting nut
changes t he preload 61 N (6.2 kg, 14IbXKXSoo: 64N
{6.S kg, 14 Ib))turn.
eThe standard adjusting nut position from the center
of t he upper mounting hole is 112 mm (KX2S0, 500:
111 mm). The adjustable range is 104-124 mm.
SUSPENSION 11-15
A. Adjusting Nut Position C. Adj usting Nut
B. Locknut.
- Tighten the locknut securely.
- After adjusting, move the spring up and down to
make sure that the spring is seated.
-I nstall the parts re moved.
Re8r Shock Absorber Remov8!
- Remove the following parts .
Seat
Right and l eft Side Covers
Si lencer
Rear Frame and Ai r Cleaner case.
. Place a stand or block under the motorcycle so that
t he rear wheel is ra ised off the ground.
- Remove t he tie-rod mounti ng nut, and pull out
the mounting bolt.
- Remove the rear shock absorber lower mounting
nut, and pull out the mounting bolt.
- Remove t he rear shock absorber upper mounting
bolt, and pull the rear shock absorber down and
out.
A. Tie-Rod Front Mounting Nut
B. Rear Shock Absorber Lower Mount ing Bolt
11-16 SUSPENSION
A. Rear Shock Absorber
B. Rear Shock Absorber Upper Mounting Bolt
oWhen pulling out the mounting bolts, lift the resr
wheel slightly. Forcing or tapping on a bolt could
damage the bolt. sleeve. and bearing.
Rear Shock Absorber Installation Notes
- Instal lation is the reverse of removal.
- Tighten the rear shock absorber upper, lower and
tie-rod front mounting nuts to the speci fied torque.
Tightening Torque:
Rear Shock Absorber Nut (Upper and Lower) :
34 N-m 13.5 kg-rn. 25 ft-Ib)
Unitrak Tie-rod Nut:
81 N-m (8.3 kg-m. 60 ft-Ib)
Reaf Shock Absorber Spring Replacement
In addition to the standard spring, heavy and
light springs are avail able. If the standard spring is
improper for your purpose, select a proper one ac-
cording to the rider' s weight or course conditions.
-Remove the fol lowing parts.
Seat
Right and left Side Covers
Silencer
Rear Frame and Air Cleaner case
-Remove the rear shock absorber.
- Clean the threaded portion on the upper of the rear
shock absorber.
-Hold the upper of the rear shock absorber with a
vise.
' Using the hook wrenches (special tools), loosen the
locknut and turn the adjusting nut all way down.
A. Adjusting Nut C. Hook Wrenches: 570011101
B. locknut
- Slide down the rubber bumper.
-Remove the spring retainer clip from the shock
absorber and tift off the spring.
A. Retai ner Clip B. Spring
- Exchange the spring for an optional part.
-I nstall the spring and retainer dip.
- Adjust the spring preload (see Spri ng Preload Ad
justment).
- I nstall the rear shock absorber so that small er
diameter end faces upward.
A. Smal ler Diameter End
Rear Shock Absorber Disassembly (Oil Change)
The oil should be changed in the rear shock ab-
sorber at least once per racing season. The f requency
for best performance must be based upon riding
conditions and rider ability.
- Remove the rear shock absorber from the frame
(see Rear Shock Absorber Removal).
- Remove the shock absorber spring (see Rear Shock
Absorber Spring Replacement).
-Point the valve away from you. Slowl y release nitro-
gen gas pressure by pushi ng down the valve core
with a screwdri ver.
A. Gas Reservior B. Valve
I WARNING'
aBe sure to point the reservior valve away from you
when releasing nitrogen gas pressure. An oil mist
Is often released with the nitrogen.
aAlways release nitrogen gas pressure before ex-
plosive separation of partl .
_Remove the air bleeder bolt, and pump the rear
shock to drain t he oil out of the rear shock body
and t he gas reservoir.
A. Air Bleeder Bolt
SUSPENSION' ' -'7
- Using the suitable tool and press, push the reservoir
cap in 10 mm.
A. Suitable Tool B. Press
- Remove the d rclip from the gas reservoi r.
A. Circl ip
-Pull the gas reservoir cap out of the gas reservoi r.
A. Pliers
-Pour t he remaining oil out of t he gas reservoi r.
11-18 SUSPENSION
- Adjust t he ga5 reservoir damping adjuster to the
softest position.
-Hold the upper end of the rear shock with the vise
again .
Pry or tap at the gaps in the stop with suitable tools
to free t he stop from the rear shock body.
A

A. Caps B. Tap
- Slide the stop up to the top of the push rod then
lightly tap around the seal with a suitable rod and
mallet, and push the seal assembly 10 mm down.
Remove the circli p.
A. Ci rclip
-Ughtly move the push rod back and forth, and pull
out the push rod assembly.
- Pour the oil out of the rear shock body.
Rear Shock Absorber Assembly Notes
- Assembl y is reverse of disassembly,
- Adjust the gas reservoir damper adj uster to the
softest position.
-I nstall the air bleeder bolt.
OCheck the O-ring on the air bleeder bolt, and re-
place it if necessary .
Pout KYB K2.c (SAE 5W or Bel-Ray SE2 *40) oil
into the gas reservoir to 60 - 70 mm from the
gas reservoir upper end.
A. 60-70 mm
- Check that the bladder on t he gas reservoir cap is
not partially collapsed.
- If it is. push down t he valve core with a screwdri ver.
- Check the bladde r for sign of damage or crack. If
necessary. replace it with a new one .
J(8)
A. Bladder B. Up

000 not use a damaged or partially collapsed blad
der. because it may burst. gently reducing re.r
shock performance.
- Apply grease to the lip of the bladder.
- Push the bladder into the gas reservoi r slowly until
it just clears the circiip groove. Wipe out any
spil led oi l.
oEnsure that no air remains in the system.
- Check the circlip for weakening, deformity and
flaws. If necessary, replace it with a new one.
I WARNING'
olf weakened. deformed or flawed clrclip is used,
the gas reservoir cap may not hold when Injecting
the nitrogen gas. This would allow oil and internal
parts to explode out of the reservoir.
- Mount the circli p in the groove in the gas reservoi r.
A. Ci rclip
-Pull up the gas reservoir cap against the circlip.
The end of t he gas reservoir cap must align with
the end of the gas reservoir.
A. Gas Reservoir Cap C. Aligned
B. Gas Reservoir End
SUSPENSION 11 19
I WARNING'
olf the end of the gas reservoir cap and the end of
the gas reservoir are not aligned. the circlip is not
correctly fitted In the groove In the gas reservoir
or is deformed. In this case, the oil and internal
parts could explode out of the reservoir when
injecting the nitrogen gas or while riding the
motorcycle.
-Pour KYB K2-C (SAE 5W or Bel-Ray SE2 '40) oi l
into the rear shock body to 45 mm f rom the lower
end ot"the rear shock body.
A. 45 mm
- Insert t he piston end of the push rod assembl y into
t he rear shock body slowly. and pump the push
rod until all the air is forced out of the rear shock
body.
A. Piston B. Seal Assembl y.
- Push the seal assembly into the rear shock body
until it just clears the circlip groove.
- Check the circlip. If it is deformed or damaged, re-
place it with a new one.
- Fit the ci rcl ip into the groove in the rear shock body.
, , -20 SUSPENSION
[
olf the circlip is not 8 certain fit In the groove in
the rear shock body. the push rod .... mbly may
come out of the shock absorber when in;actlng
the nitrogen gas or riding the motorcycle.
A. Circlip
- Pull up the push rod assembly against the c!rcl1p,
&Force the stop into the rear shock body by lightly
tapping around the edge of the stop with a mallet.
eHold the lower end of the push rod assembly with a
vise .
Pump the rear shock up and down several times, and
then leave it in the fully extened position for about
three minutes.
_Remove the air bleeder boh from the upper part of the
rear shock body.
A. Air Bleeder Bolt
11 If oil comes out of the air bleeder screw hole. let it
overflow until it stops.
* If oil does not come out of the air bleeder screw
hole, add the specified oil into the air bleeder
screw hol e until it overflow (that is, unti l all the
remaining air is forced out) .
Install the air bleeder screw securely.
Fully extend the push rod assembly.
- Injection nitrogen gas to a pressure of 50 kPa
(0.5 kg/em:. 7 psi) through the valve on the gas
reservoir.
Check the rear shock body and gas reservoir for oil
and gas leaks.
* If there are no leaks, inject the nitrogen gas up to
the specified pressure. The adjustable gas pres-
sure range is 1000 - 1500 kPa (10 - 15 kg/cm
l

142 - 213 psi) and the factory standard gas
pressure is 1200 kPa (12 kg/cm
l
, 170 psi).
I WARNING.
oPressurize the gas reservoir with nitrogen gas only.
Do not use air or other gases, since they may
cause premature wear, rust, fira hazard or sub-
standard performance.
OHigh pressure gas is dangerous. Have a qualified
mechanic perform this procedure.
- Install the spring and retainer clip.
- Adjust spring preload. Reinstall the rear shock
absorber.
Scrapping
I WARNING.
oSinca the rear shock absorber contains nitrogan
gas, do not incinerate or disassemble the rear
shock absorber .
oBafore a rear shock absorber Is scrapped. reple
the nitrogen gas completely. Do not point the
valve to your face or body then.
A. Valve
Swing Arm:
Swing Arm Removal
_Remove the rear wheel (see Rear Wheel Removal
in the Wheel(Tires chapter).
_Remove the tie-rod rear mounting bolts.
- Pullout the swi ng arm pivot shaft. and remove the
swi ng arm.
-Separate the chain guides and chain slippers from
the swing a rm.
Swing Arm Installation Notes
- Apply plenty of molybdenum disulfide grease to
the inside of the needle bearings and sleeves.
- Tighten the swing arm pivot shaft nut, and the
tie-rod rear mounting nut to the specified torque.
Tightening Torque:
Pivot Shaft Nut :
78 N-m (8.0 kg-rn, 58.0 ft -Ib)
Tie-rod Rear Mounting Nut:
81 N-m (8.3 kg-m. 60 ft -Ibl
-Refer to the WheelsfTi res, Final Drive. and Brakes
chapters for wheel installation.
Tie-Rod, Rocker Arm:
Tie-Rod Removal
- Place a stand or block under the motorcycle so that
- Remove the tie-rod front mounting bolt.
- Remove the tie-rod rear mounting bolt, and then
take out the tie-rods.
;;,;;;;,.-----
A. Tie-Rod Front Mounting Bolt C. Tie-Rod
B. Tie-Rod Rear Mounting Bolt
SUSPENSION 11 -2 1
Tie-Rod Installation Notes
- Apply ple nty of molybdenum disulfide grease to
the inside of the needle bearings, and oi l seals.
- Tighten the tie-rod fron t and rear mounting nuts to
Tightening Torque:
81 N-m {8.3 kg-m, 60 ft -Ibl
Rocker Arm Removal
-Place a stand or block under the motorcycle so that
- Remove the tie-rod front mounting bolt.
-Remove the rear shock absorber lower mounting
bolt.
-Remove the rocker arm pivot shaft.
A. Tie-Rod Front Mounting Boh
B. Rear Shock Absorber Lower Mounti ng Bolt
C. Rocker Arm
A. Rocker Arm Pi vot Shaft
-Remove the rocker arm.
, , -22 SUSPENSION
Rocker Arm Installation Nores
. 'nstallation is the reverse of removal .
- Apply plenty of molybdenum disulfide grease to
the inside of the rocker arm hole. outside of the
sleeve. and spherical bearings.
-Tighten the following parts to the specified torque.
nghtenlng Torque:
Rocker Arm Nut:
81 N m 18.3 kg-m. 60 h lb)
ne-rod Nut :
81 N-m 18.3 kg-m. 60 ft-Ib)
Unl-trak Maintenancee
Check the uni-trak component parts for wear peri-
odical ly, or whenever excessive play is suspected.
- Put a sturdy block under the engine so that the
tear wheel is raised off the ground.
Push and pullan the swing arm, up and down. to
check for wear.
A. Swing Arm
A small amount of play on the swi ng arm is normal
and no corrective action is needed. However, if
excessive play is felt . remove the unHrak pam
from the frame and check for wear .
... If any spherical bearing is worn past the service
limit. replace it using a press and a suitable driver.
[ WARNING'
oln.tall.tlon of new .pherlcal bearing(al in the uni-
trak link may cause too stiff re8r suspension.
Testrida the motorcyc" sIowty and prudently until
the suspension becomes normal.
Sleeve:
Pull out the sleeve of the rocker arm. and measure
the outside diameter of the sleeve .
... If the sleeve is worn past the service limit. replace
the sleeve.
A. Sleeves
Sleeve Outside Diameter
Standard:
Service limit :
Rocker Arm:
Mounting Bolt Bend
21 .987 - 22.000 mm
21.85 mm
A bent bolt causes vibration. poor handling, and
instabil ity.
To measure bolt runout. remove the bolt, place i t
in V blocks. and set a dial gauge to the bolt at a
point halfway between the blocks. Turn the bolt to
measure the runout. The amount of dial variation
is the a mount of runout.
A. Turn
* If runout exceeds the service li mit. replace the
bolt.
Bolt Runout
Sbindard:
Ser,ice Limit:
under 0.1 mm
0.2 mm
SUSPENSION 11-23
STEERING 12-1
Steering
Table of Contents
Exploded View ............ . ...... ...... ,' , ........ . " ...... ,' .......... .. ...... , 2-2
Special Tool s .... .... . .................. . .. ......... ..... ... .. ............ .. . ... 12-3
Steering Adjustment .. ............... .. ... ..... _. ' .... '.. .. . . ......... .. ...... ..... 12-4
Steering Inspection . .... .. ..... _._ .. .. .. . _. _ .... . .... . . ..... .. .. _ _, _.. .. . 12-4
Steering Adjustment ....... .. .. .. . ..... .. ........ .... ... ... .. .. ... .. ... ... ... .. 12-4
Steering Removal/Installation ..... " . .... .. .. . . ....... " .. .. ..... .. .. ... .. . .... .. 12-5
Steering Stem Removal .. ............ .... . ....... .. ... . .. .... ...... . . ..... .. 125
Steering Stem Installation Notes . . .. . ....... .. . ... . ... .. ... . .. . .. . .. ..... 12 5
Steering Stem Race Removal .... .. .. .. ... .. ...... . . ..... . .. . ............. 125
Steering Stem Race Installation Notes . . .. .. ...... ... .. .. . . ... . . . . . .. ... 126
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
_1
,
,
KX250. 500 ..... .., ... I
--: i P ~
KX250, 500
, --------- -------7
I fl /
/
I
/
/
I
/
/
/
.. /
I
I
/
I
/
I
'- ______ ____ _ _ ...1
@ ,.
Q
Tl : 25 N m {2.5 kg-m. 18 ft-Ibl
T2: 44 Nm f4.6 kg-m, 33 ftlbl
T3: 3.9 Nm (0.4 kg-m. 36 In-Ib)
T4: 20 Nm (2.0 kg-m. 14.6 ft-Ibl
l __ - - - -' :::===
r - - -7
, I
/ '
/ '" ~ " I U I
'- ____ -1
I 1
1 1
1 I
I
L __
Special Tools
Stem Nut Wrench: 5700' -1100
Bearing Driver Set: 5700' -"29
Stem Bearing Driver : 57001-137
Stem Bearing Driver Adapter: 57001 1074
STEERING 12-3
Stem Bearing Remover: 51001-' 107
Driver Press Shaft : 6700' -'075
Driver:
67001-1106 57001-1076
12-4 STEERING
Steering Adjustment
Steering Inspection
. Place a stand or block under the motorcycle so that
the front wheel is raised off the ground.
- With the front wheel pointing straight ahead, alter-
nately nudge each end of the handlebar. The front
wheel should swi ng fully left and right from the
force of gravity until the fork hits the stop .
... If the steering binds Of 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 feel looseness, adjust the steering.
Steering Adjustment
-Place a stand Of block under the motorcycle so that the
-Remove the steering stem head nut and loosen the
front fork upper damp bolts.
-Pull out the handlebar and steering stem upper bracket
from the steering stem.
A. Stem Head Nut
Tum the steering stem locknut with the stem nut
wrench (special1:!x>l) to obtain the proper adjustment.
A. Stem Locknut
B. Stem Nut Wrench: 57(:011100
* If the steering is too tight. loosen the stem locknut a
fraction of a tum; if the steeri ng is too loose, tighten
the locknut a fraction of a tum. Tum the locknut
1/8 tum at a time maximum.
Install the upper bracket and handle.
Tighten the steering stem head nut to the specified
torque.
TIghtening Torque
44 N-m 14.5 kg-m. 33 1t-l>I
-Tighten the front fork upper clamp bolts to the
specified torque.
Tigf1tonlng T 0<qU8
20 N-m 12.0 kg-m. 14.5 t ~ b l
Steering Removal /Installation
...... .......................................... ...............
Steering Stem Remova/
- Remove the foll owing parts.
Front Wheel
Brake Hose Clamp
Caliper Mounting Bolts
Master Cylinder Clamp
Front Fender
Handlebar
Front Fork
- Remove the steering stem head nut and washer.
- Remove the steering stem head.
- Push up on the stem base. and remove the steering
stem locknut with the stem nut wrench (special tcoll
then remove the steering stem and stem base.
A. Stem Base
B. Stem Nut Wrench : 570011100
C. Steering Stem Locknut
D. Steering Stem
- Remove the upper tapered roller bearing inner race.
A. Tapered Roller Bearing
Steering Stem Installation Notes
STEERING 12-5
- Apply grease to the upper tapered roller bearing and
put it on the outer race .
- Using the stem nut wrench (special t o l ~ temporarilly
tighten the stem locknut to press the steel balls or
tapered roller bearing against the outer race.
- Back out the stem locknut a fraction of a tum until
it turns lightly and then tighten the stem locknut to
the specified torque agai n.
TIghtening Torque
3.9 N-m 10.4 kg-m. 35 in-Ibl
- Connect the connectors, and route them accordini
to the Cable and Wire Routing section in the Ceneral
information chapter.
- Tighten the stem head nut to the specified torque.
TIghtening Torque
44 N-m 14.6 kg-m, 33 tt...,.
-I nstall the parts removed (see appropriate chapters).
- Route the cables. hoses. and harnesses according to
the Cable. Hose and Wire 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
Front Brake
Clutch Cable
Throttle Cable
Steering Stem Race Removal
- Remove the steering stem.
-Remove the outer races from the head pipe.
ORemove the outer races pressed into the head pipt.,
using the stem bearing remover (special tool) as shown
below. and hammer the stem bearing remover to drive
it out
NOTE
olf either steering stem bearing is damaged, ;r is
recommended that both the upper and lower
bearings (including outer l7JCes) should be l"fJp/8ced
with new ones.
Outer Race Removal
1. Stem Bearing Remover: 570011107
12-6 STEERING
- Remove the tower inner race (with its grease seat)
which is pressed onto the steering stem.
A. Roller Bearing
Steering Stem Race Installation Notes
' Installation is the reverse of removal.
' Apply grease to the outer races, and then drive
them into the head pipe using the drivers and the
driver press shaft (special tools),
Outer Race Installation
1. Driver Press Shaft: 57001-1075
2. Driver: 5700""06
3. Driver: 57001-1076
t Apply grease to the lower tapered roller bearing,
and drive it onto the steering stem using the stem
bearing driver and adapter (special tools).
A. Stem Bearing Driver: 57001-137
B. Adapter: 57001-1074
' Apply grease to the upper tapered roller bearing
and put it on the outer race.
' Refer to Steering Stem Installation Notes.
.... ................. _ ....... . _ .......................... _ .. .
Steering Maintenance
....... .... ........................... .... ...................
Steering Stem Bearing Lubrication
Remove the steering stem (see Steering Stem Re-
moval ).
Using a high f lash-point solvent, 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
and dirt.
Vis uall y check the outer races and the rollers.
* Replace the bearing assemblies if they show wear
or damages.
Pack the upper and lower tapered roller bearings
in the cages with grease, and apply a light coat
of grease to the upper and lower outer races.
A_ Steering Stem (tape red roll er) Bearings
B. Crease Seal
-Install t he steering stem, and adj ust the steering
(see Steering Stem Instal lat ion, Steering Adjust-
ment).
Bearing Wear, Damage
Using a high flash-point solvent. wash the upper
and lowe r tapered rollers in the cages, and wipe
the upper and lower outer ra ces, which are press-
fitted into the frame head pipe, clean off grease
and dirt.
Visually c heck the outer races and the rollers.
* Replace the bearing assemblies if they show
damage.
STEERING 12-7
Steering Stem Warp
Whenever the steering stem is removed. or if t he
steering cannot be adjusted for smooth action,
check the steering stem for strai ght ness.
* If the steering stem shaft is bent, replace the steer-
ing stem.
ELECTRICAL SYSTEM 13-1
Electrical System
Table of Contents
Wiring Diagram .. .. . ..... . .. . .. .. .. .. . .... .. .... ...... .. ... .. . ... . .. .. ........... .. ... 13-2
Exploded View ............... ................................................. ........ 13-3
Specifications
Special Tools
13-5
, 3-6
Precautions ............................. . ................ ............................. 13-7
Electrical Wiring . .. ... ... ........ .. . .. .. . ... .. . . ..... . .. . .. .. . .. . ... .. . ..... . . . .. . . 13-7
Wiring Inspection .. . ... _, ......................... ....... .. ... . . . .. _,_..... . . 13-7
Ignition Timing ............. . .................. . .. . ................. .. ............ ,... , 3-8
Ignition Timing Adjustment ..................................... ..... ..... 13-8
Flywheel Magneto ... .. . ................... ......... .... ... .... ... .. . . . ..... ..... . .... 13-9
Flywheel Magneto Removal ." ............ ......... .. ........ .. .. ..... . .. ... 13-9
Flywheel Magneto Installation ...................... ....... ..... ........... , 3-9
Flywheel Magneto Inspection ............................. ...... ..... ".... 13-9
Ignition System . ................. . . ....... . ........... .. .. ...... .. . ... ..... . ... ...... 13- 11
Safety Instructions .................... .. ........ ..... ... .. . ... ........ .... .. . 13-11
Ignition Coil Removal ............. ... .... .......... ..... ... ..... ............. , 3- 11
Ignition Coil Installation ...... ................. ........ .. ..... ........ .. .... 13-11
Ignition Coil Inspection ............. .... ...... .. ... .... ....... ..... ......... , 3- 1 1
Spark Plug Cleaning and Inspection ...... .................... ...... .... 13- 12
Spark Plug Gap Inspection ... ........... ........ .... .......... .... ........ 13- 12
COl Unit Inspection .......................... .................. .. ......... . .. 13-12
Stator Coil Inspection ...... " ... " ........ ......... ...... ... .... ......... . .. 13- 14
13-2 ELECTRICAL SYSTEM
Wiring Diagram
SPIn; Plug
__ .,. __ ~ . - . - . - ~ - - 8''''' ~ B"'" ______ -(----')
B.'"
Engine :" ....
SIOCI! !
Bunon L ._ . .J
3PConnKtl)(
.. . ..... . .... ..... .
d ... d .. V .. i .. . w ....
........ .......... .................. .............. .
KX250,
IUK)

.
.
ELECTRICAL SYSTEM 13 3
T4
KX500,
T3
T1 : 5.9 N-m (0.6 kg-m. 62 in-Ib)
T2: 22 N-m 12.2 kg-m. 16 ft-Ib)
T3: 9.8 N-m '1 .0 kg-m. 87 in-Ib)
T4: 27 N-m (2.8 kg-m. 20 ft-Ibl
T5: 27 N-m 12.8 kg-m. 20 ft-Ib)
T6: 78 N-m 18 kg-m. 58 ft-Ibl
Ia--@
(UK) : U.K. Model
SPECIFICATIONS
Item
Ignition System:
Ignition timing: KX125
KX250
KX500
Ignition coil:
3 needle arcing distance
Primary winding resistance
Secondary winding resistance
COt unit internal resistance
Spark plug: KX125
KX250
KX500
Spark plug gap
: Canadian model
@' U. K. model
Standard
13 BTDC @11000r/min (rpm)
13 BTDC @6000r/min (rpm)
17 BTDC @6000r/min (rpm I
7 mm or more
1.00 + 15%
5.9 KO + 15%
rsferto 13 - 13
NGK B10EG @ NGK BR10EG
NGK B9EG @ NGK BR9EG
NGK BBEG @ NGK BRBEG
0.6 - 0.7 mm
136 ELECTRICAL SYSTEM
Special Tools
Along with common hand tools, the followin g
more speciali zed tools are required for complete
electrical system servici ng.
Rotor Holder: 57001-1248
Rotor Holder Adapter "A": 57001 -1108
Flywheel Puller: 57001 -252
Coil Tester: 57001 -1242
Hand Tester : 57001 -983
Spark Plug Wrench. Hex 21 : 57001 - ' 10
NOTE
oThe flywheel holder (PI N 57001-1313) can be
used i nstead of the rotor holder (PI N
57001 1248).
Precautions
There are a number of important precautions that
are musts when selVicing the electrical system. learn
and obselVe all the rules below.
oThe electrical parts should never be struck sharply, as
with a hammer, or allowed to fall 00 a hard surface.
Such a shock to the parts can damage them.
oT roubles may involve one or in some cases all items.
Never replace a defective part without determining
what CAUSED the failure. If the failure was caused
by some other item or items, they too must be r ~
paired or replaced, or the new replacement will soon
fail again.
0Make sure all connectors in the circuit are dean and
tight, and examine wires for signs of burning, fraying,
etc. Poor wires and bad connections will affect elec-
trical system operation.
OMeasure coil and winding resistance when the part is
cold (at room temperature).
oElectrical Connectors
Femme Connectors
Male Connectors
Electrical Wiri ng
Wiring Inspection
Visually inspect the wiring for signs of burning.
fraying. etc.
*If any wiring is poor, replace the damaged wiring.
Pull each connector apart and inspect it for o r r ~
sion, dirt, and damage.
* If the connector is corroded or dirty, dean it care-
fully. If it is damaged, replace it.
Check the wiring for continuity.
o Use the wiring diagram to find the ends of the lead
which is suspected of being a problem.
oConnect an ohmmet er between the ends of the
leads.
oSet the meter to the x10 range, and lead the meter.
* If the meter does not read zero 0, t he lead is de-
fective. Replace the lead o r t he wiri ng harness
if necessary.
.. ... ... .. .. ...... .. ... . .. .... .. .. ............. .. ...... .......
Ignition Timing
... .... ..... ........................... ........ ........ .......
Ignition Timing Adjustment
Remove the magneto cover .
Check to see if the mark on the magneto stator is
ali gned with the mark on the crankcase.
* If the marks are not aligned. loosen the magneto
stator screws and turn the magneto stator.
KX125:
A. Timing Mark (Crankcase)
B. Timing Mark (Stator Plate)
C. Screw
D. Magneto Stator
KX250:
B. Timing Mark (Sta tor Plate)
C. Screw
D. Magneto Stator
KX500:
B. Timi ng Ma rk (Stator Plate)
C. Screw
D. Magneto Stator
-Tighten the screws securely.
- Install the magneto cover.
Flywheel Magneto
Fl ywheel Magneto Removal
'Remove the magneto cover.
'Hold the flywheel steady with the rotor holder
and adapter " A" (special toolsl. and remove the fly-
wheel bolt or nut_
A. Fl ywheel Ho lder: 57001-1248
B. Adapter " A"; 57001-1108
- Remove the rotor holder and adapter "A".
-Screw the flywheel puller (special tool) into the fly-
wheel by turning it countercl ockwise (left-hand
thread).
- Remove the flywheel from the crankshaft by turning
in the pull er center bolt and tapping the head of the
bolt lightly with a hammer, while holding the puller
body steady. There is a woodruff key in the crankshaft
tapered portion.
oNever 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.
A. Flywheel Pull er: 57001-252
- Unscrew the mounting screws, and remove the stator
and the wiring grommet.
A. Mounting Screws C. Wiring Grommet
B. Stator
Flywheel Magneto Installation
-I nstall at ion is the reverse of removal. Note the
following;
oUsing a high flash-point solvent, clean off any oil or
dirt that may be on the crankshaft taper or in the
hole in the fl ywheel. Dry them with a clean doth.
A. Clean Off
oSet the stator wiring grommet securely in the notch in
the left crankshaft half, and route the wires according
to the Wire Routing section in the General Information
chapter.
A. Stator Lead
B. Grommet
oFit the woodruff key securely in the slot in the
crankshaft before installing the flywheel .
oHold the flywheel steady with the rotor holder and
adapter " AU (special tools), and tighten the flywheel
bolt or nut to the specified torque.
TIghtening Torque:
KX126 (Bott): 22 N-m 12.2 kg-m. 16.0 ft-ibl
KX260 IBoItI: 27 N-m 12.8 kg-m, 20 ft4bl
KX600 (Nut) : 78 Nm 18 kg-m. 58 ft-Ibl
A. Rotor Holder: 57001-1248
B. Adapter "A": 57001-1108
OReplace the gasket if it is hardened or damaged.
Flywheel Magneto Inspect;on
There are three types of magneto problems: short.
open (wire burned out), or loss in flywheel magnetism.
A short or open in one of the coil wires will result
either a tow output, or no output at all. A toss in
f l ~ h e e l magnetism. which may be caused by dropping
or hitting the f I ~ h e e l or just by aging. wilt result in
tow output Inspect the coi ls and the flywheel (see
Ignition System).
... ......... ....... ....................... .... .... .. .... ... ..
Ignition System
................ ......... ............ ....... ....... .... .. ....
Safet y Instructions
I WARNING'
oTho Ignition system produces ex1nHneIy high _.
Do not touch the spark plugs. high tension coils. or
spark plug leads while the engine Is running, or you
could receive 8 severe shock.
Ignition Coil Removal
-Remove the foll owing parts.
Seat
Radiator Cover
Fuel Tank
- Disconnect the ignition coi l pri mary leads.
- Pull the plug cap off the spark plug.
- Unscrew the mounting bolt, and remove the ignition
coil.
A. Ignition Coi l C. Plug Cap
B. Primary Lead
Igni tion Coil Installation
Igni tion Coil Inspection
Measuring arcing distance:
The most accurate test for determini ng the condition
of the ignition coil is made by measuri ng arcing
distance with coil tester (special tool) tester usi ng the
meth()d.
NOTE
OSince a tester other than the call tetter (special tool:
57001-'242) may produce a different arcing distance,
the coil telter ($p8Cial tool: 57001 1242) is recom-
mended for reliable results.
- Remove the ignition coil.
- Connect the ignition coil (with the spark plug cap
left install ed on the spark plug lead) to the tester, and
measure the arcing distance.
Ignition Coil Test
"
10 k
@ e
1Il?0 @

0
1. Coil Tester: 57001-1242 2. Ignition Coil
I WARNING'
oTo avoid extremely high vottage shocks, do not
touch the coB or lead.
* If the distance reading is less than the specified value.
the ignition coil or spark plug cap is defective.
Ignition Con Arcing Distance
7 mm or more
- To determine which part is defective, measure the
arcing distance agai n with the spark plug cap re-
moved from the ignition coil lead.
* If the arcing distance is subnormal as before, the
trouble is with the ignition coil itself. If the arcing
distance is now normal, the trouble is with the spark
plug cap.
Measuring coil resistance:
If the arci ng tester is not available, the coil can be
checked for a broken or badl y shorted winding with
an ohmmeter. However, an ohmmeter cannot detect
layer shorts and shorts resulti ng from insulation break
down under high voltage.
- Remove the ignition coil.
- Measure the primary winding resistance.
OConnect an ohmmeter between the coil terminals.
oSet the meter to the x 1 n range, and read the meter.
- Measure the secondary winding resistance.
oPull the spark pl ug cap off the lead.
OConnect an ohmmeter between the spark pl ug lead
and the ground lead terminal.
OSet the meter to the x 1 kO range. and read the meter.
* If the meter does not read as specified, replace the
coil.
Ignition Coil Winding Resistance
Primary windings: ' .0 {) '5%
Secondary windings: 5.9 kO 15%
Ignition Coil Winding Resistance
(J)
6
(5
--
./
(j)
1. Measure primary winding resistance.
2. Measure secondary winding resistance.
3. i gnition Coil
* If the meter reads as specified, the ignition coil
windings are probably good. However, if the ignition
system still does not perform as it should after all
other components have been checked, test replace
the coil with one known to be good.
Check the spark plug lead for visible damage.
* If the spark plug lead is damaged. repl ace the coil.
Spark Plug Cleaning and Inspection
Remove the spark plug, and visuall y 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.
Spark Plug Gap Inspection
- Measure the gap with a wire-type thickness gauge.
*I f the gap is incorrect, carefull v bend the side
electrode with a suitable tool to obtain the cor-
rect gap.
S""",, Plug Gap
0.6 - 0.7 mm
Spar!< Plug Gap
1. Insulator
2. Center Electrode
CDI Unit Inspection
- Remove the seal
- Remove the fuel tank.
3. Plug Cap
4. Side Electrode
- Disconnect the CDI unit lead.
- Unscrew the mounting bolt, and remove the COl unit
A. ~ n t i n Bolt B. COl Unit
OUse only KawasakJ Hand Tester 57001-983 for
this test. A tester other than the Kawasaki Hand
Tester may show dffferent readings.
000 not use a megger or a meter with a large-
capactty battery, or the COl unit wll be damaged.
- Set the Kawasaki Hand Tester to the x 1 kG
range, connect the Tester to the terminals in the
cor unit lead, and check the internal resistance
as shown in the following the table.
* If t he readings do not correspond to the table,
replace the COl uni t.
ELECTRICAL SYSTEM 1313
COl Unit Test Using the Kawasaki Hand Tester
KX125:
Tester Posi ti ve (+) l ead Connection
0
lead Color
Black/White White/Red White/Green Bl ack
.2 (Exciter) (Pickup) (Pickup) (Ign. (oil )
U
~
500 KO' 500 kO' 500 ko-
0
BlackfWhite
0
1 1 1
0
( Exciter)
U
~ ~ ~
'C
~
White/Red

6.2 - 7.2 kO
(Pickup)
~ ~
-
I
~
White/ Green
~

~ 5.2 - 5.9 KO ~

(Pick up)
-

Black
~
11.2 - 15.2 KG 2. 6 - 3.7 kO
Z
(Ign. Coil)
~
0;
- BlacklYel low
-

~ 5.2 - 5.9 KO 0 ~
...
(Ground)
KX250 :
Tester Positive (+ ) l ead Connect ion
0
Lead Color
Bl ack/Whi te White/Red
.2 (Exciter) (Pickup)
-
u
~

500 Ko-
0
Bl ackfWhite
0
1
0
(Exci t er)
u
~
'C
~

White/Red

(Pickup)
~
-
I
~
White/Green

2.6 - 3.8 KO
> (Pickup)
~
~

Black

8.5 - 15 KO
z
(l gn. Coil )
~

- Black/Yell ow
-

~ 2.6 - 3.8 KO
...
(Ground)
NOTE
OAsteri$k(4): When rtIPlIating the test indicated with an
. terisk, wait fo r mort! than 30 minutes befort! next
trial to get a reliable result.
Whit e/Green Black
(Picku p) (lgn. Coi l)
500 kO' 500 ko-
1 1
~ ~
5.2 - 7 kn ~
~
~
2.6 - 3.8 kO
~
0 ~
Bl ack/Yell ow
(Ground)
500 kO
1
~
6.2 - 7.2kO
0
2.8 - 3.7 kO
~
Black/Yell ow
(Ground)
500 kO'
1
~
5.2 - 7 kO
0
2.6 - 3.8 kO
~
KX500:
Tester Positive (+) lead Connection
c
lead Color
Black/White White/Red
0
(Exciter) (Pickup)
~
u
~

c
Black/White
<
0
(Exciter)
=
u
"
White/Red

(Pickup)
=
-
I
-
White/Green

>
(Pickup)
=
~

Black

z
(lgn. Coi l)
=

- BlackIYeli ow

=
>-
(Ground)
Stator Coil Inspection
- Remove the seat and fuel tank.
- Disconnect the magneto lead.
~
=
=
=
- Zero the ohmmeter, and connect it as shown in the
table.
Stator Coli R latance
Model Connections Reading
BlackfWhite-BlacklYellow 432-6480
KX125
WhitelRed - WhiteiGreen 4.0-6.0 n
BlackNlhite- BlacklY ellow 432-648 0
KX250
White/Red-White/Creen 7.7-11.5 n
BlackIVVhite-BlackNellow 432-648 0
KX500
White/Red - White/Creen 4.0-6.00
White/Creen Bl ack BlackIYellow
(Pickup) (Ian. Coil) (Ground)
500 kO 500 kO 500 kO"
I I I
= = =
6.5 - 7.6 kO
=
6-7.6kO
~
=
0
2.7 - 3.6 kO
~
2.7 - 3.6 kO
0
=
~
Note the resistance reading.
* If there is more resistance than shown in the ta-
ble, the stator has a broken wi re, the leads be-
tween the stator and the connector are open, or
the connections are bad. Check the stator and the
leads, and fix or replace the damaged parts.
* If there is much less resistance than shown in the
table, the stator is shorted, or t he leads between
the stator and the connector is grounded. Check
the stator and the leads, and fix or replace the
damaged parts.
APPENOIX 14-1
Appendix
Table of Contents
Troubleshooting Guide ...... ,' .... , .... , ..... "...... . .. ........ .... . . .. . ........ ... 14-2
General Lubrication ...... . ... ..... " ................. " .. . ...... ,.................. ... 14-5
Unit Conversion Table ....... .... .... . ... ..... . . ... . .. . ............................ 14-6
'4-2 APPENDIX
.............. , ...... .................. .... ...... ' .......... .
Troubleshooting Guide
.. .................. ................. ........................
NOTE
o This is not an exhaustive list, giving every possible
cause for 6sch probl9m list8d. It is meant Simply 8S 8
rough guide to assist the troubleshooting for some of
the more common difficulties.
Engine Doesn' t Start; Starting Difficulty:
Engine won' t tum over:
Cylinder, piston seizure
Cranksha ft seizure
Connectins rod small end seil urs
Connecting rod big end seizure
Transmission gear or bearing seizure
Kick shaft return spring broken
Kick ratchet gear not engagi ng
No fuel flow:
No fuel in tank
Fuel tap turned oH
Tank cap air vent obstructed
Fuel tap clogged
Fuel line clogged
Float va lve clogged
Engine flooded,
Float level too high
Float valve worn or stuck open
Starting technique faulty
(when flOlXled, kick with the throttle fully open
to allow more air to reach the engine.)
No spartl;; sparte we. :
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap not in good contact
Spark plug incorrect
COl unit trouble
Ignition coil trouble
Ignition coi l resistor open
Flywheel magneto damaged
Wiring shorted or open
Fuel/air mixture incorTect:
Idle adjusting screw maladjusted
Slow jet or air passage clogged
Air cleaner clogged, poorly sealed, or miSSing
Starter jet clogged
CompresskK1 Low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cyli nder, piston worn
Pi ston ri ng bad (worn, weak, broken, or sticking)
Pi ston ring/land clearance excessIVe
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Cylinder nut loose
Poor Running at Low Speed:
Spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wi ring trouble
Spark plug cap shorted or not in good contact
COl unit trouble
Fuet/air mixture incorrect:
Idle adjusting screw maladjusted
Slow jet or air passage clogged
Air cleaner clogged, poorly sealed, 01' missing
Starter plunger stuck open
Float level too high or too low
Fuel tank ai r vent obstructed
Carburetor holder loose
Air cleaner duct loose
Compt'es.ion low:
Spark plug loose
Cyl inder head not sufficiently tightened down
Cylinder, piston worn
Pi stOll ring bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
Reed val ve damaged
Cylinder nut loose
KIPS ports stuck open:
KJ PS exhaust valve stuck open (valve seizure, or
carbon accumulation)
KIPS exhaust valves assembled incorrectly
Exhaust advancer spring damaged
Exhaust valve operating rod seizure
Rod (for KIPS) seized in cylinder
Other:
COl unit trouble
Transmission oil viscosity too high
Brake draggi ng
Poor Running or No Power at High Speed:
Aring incorrect:
Spark plug dirty, damaged, or maladjusted
Spark plug cap or high tension wi ring damaged
Spark plug cap shoned or not in good contact
COl unit trouble
Fuel/air mixture incorrect;
Main jet clogged or wrong size
Jet needle or needle jet worn
Jet needle clip in wrong position
Air jet or air passage clogged
Ai r cleaner clogged, poorly sealed, or missing
Fuel to carburetor insufficient
Water or foreign matter in fuel
Fuel tank air vent obstructed
Air cleaner duct loose
Fuel tap clogged
Fuel line clogged
Compression low;
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
Reed valve damaged
Cylinder nut loose
Engine rpm wil not rise properly;
Main jet dogged
Throttle valve does not full y open
Air deaner dogged
Muffler clogged
Water Of foreign matter in fuel
Cyl inder exhaust port clogged
Brake dragging
Clutch sli pping
Overheating
Transmission oil level too high
Transmission oil viSCOSity too high
Crankshaft bearing worn or damaged
KIPS portS stuck closed;
KIPS ports stuck closed
KIPS exhaust valves stuck closed
(valve seizure, or carbon accumulation)
KIPS exhaust valves assembled incorrectly
KIPS ports clogged (carbon accumulation)
Exhaust valve operati ng rod seizure
Rod (for KIPS) seized in cylinder
Knocldng, .
Carbon built up in combustion chamber
Fuel poor qual ity or incorrect
COl unit trouble
Overheating:
Firing incorrect:
Spark pl ug dirty, broken, or maladjusted
COt unit trouble
APPENDIX 14-3
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level in carburetor float bowl too low
Air deaner poorly sealed, or missing
Air cleaner duct poorly sealed
Air cleaner dogged
Compression high:
Engine load faulty:
Brake dragging
Clutch sl ipping
Transmission oil viscosity too hi gh
lubrication inadequate:
Transmi ssion oi l level too low
Transmission oi l poor quality or incorrect
Coolant Incorrect:
Coolant level too low
Coolant deteriorated
Cooting system component incorrect:
Radiator clogged
Radiator cap trouble
Water pump not rotating
Clutch Operation Faulty:
Clutch sipping:
No dutch lever play
Clutch cable maladjusted
Clutch inner cable catching
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
CkJtch not disengagng properly:
Clutch lever play excessive
Clutch plate warped or too rough
Clutch spring tension uneven
Transmi ssion oil deteriorated
Transmission oil viscosity too high
Clutch housing frozen on drive shaft
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn' t go into ge8I: shift pedal doesn' t return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift drum broken
14-4 APPENDIX
Jumps out of g8ar:
Shift fork worn
Gear groove worn
Gear dogs and/Of dog holes worn
Shift drum groove worn
Gear positioning lever spring weak Of broken
Shift fork guide pin worn
DriVf! shaft, output shaft. and/or gear splines worn
0. ......... ,
Gear positioning lever spring weak or broken
Shift mechanism arm spring broken
Abnormal EngIne Noise:
Knocking,
COl unit trouble
Fuel poor quality or incorrect
Spar\( plug incorrect

Aston slap:
Cylinder/piston clearance excessive
Cylinder. piston worn
Connecting rod bent
Piston pin, piston pin holes worn
Ottw noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring wom, broken or stuck
Piston seizure. damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Abnonnal Drive Train Noise:
Clutch noise,
Clutch OOusing/friction plate clearance exccessive
Clutch housing gear/primary gear backlash excessive
Metal chip jammed in clutch housing gear teeth
TI'8I'1Smiuion noise:
Crankcase bearing worn or damaged
Transmission gear worn or chipped
Metal chip jammed in sear teeth
Transmission oil insufficient or too thin
Kick ratchet gear not properly disengagi ng from
kick gear
Output shaft idle gear worn or chipped
Drive chain noise:
Drive chain adjusted improperl y
Chain worn
Rear and/or engine sprocket(s) wom
Chain lubrication insufficient
Rear wheel misaligned
Abnonnal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Cali per trouble
Cylinder damaged
Othe< noise
Bracket, nut. bolt. etc. not properly mounted Of
tightened
Exhaust Smoke:
Excessive wtvte amoke:
Throttle cable maladjusted
Brownish smoke:
Air cleaner clogged
Main jet too large or fallen out
Starter Plunger stuck open
Float level too high
HandNng and/or Stability Unsatisfactory:
Handlebar hard to n.n:
Control cable routing incorrect
Wi ring routing incorrect
Steering stem locknut too tight
Bearing ball damaged
Bearing race dented or wom
Steering stem lubri cation inadequate
Steering stem bent
Tire ai r pressure too low
Hancleber shakes or excessivery vibrates:
Tire
Swi ng arm sleeve Of needle bearing damaged
Rim warped, or not balanced
Front. rear axle runout excessive
Wheel beari ng worn
Handlebar clamp loose
Steering stem head nut loose
Hancleber pula to one side:
Frame berlt
Wheel misalignment
Swing arm berlt or twisted
Swing arm pivot shaft runout excessive
Steering maladjusted
Steering stem bent
Front fork leg bent
RightJleft front fork oil level uneven
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oi l viscosity 100 high
Front fork leg bent
Tire air pressure 100 high
Rear shock absorber maladjusted
(Too soft)
front fork oil insufficient andlor leaking
Front fork oil viscosity too low
Front forie, rear shock absorber spring weak
Rear shock absorber gas leaking
Rear shock absorber maladjusted
Brakes Don' t Hold:
Air in the brake l ine
Pad or di sc worn
Brake fluid leak
Disc warped
Contaminated pads
Brake fluid deteriorated
Primary or secondary cup damaged
Master cyl inder scratched insi de
Brake maladjustment (lever or pedal play x ~
cessive)
APPENDIX 14-5
...... ....... .. ......... ................... .................
General lubrication
Before lubricating each part, clean off any rusty spotS
with rust terllO\Ief and wipe off any grease. oil, dirt,or
grime.
+lubricate !he poinls listed below with indicated lubri-
cant
NOTE
o \.1Ihenever the vehicle has been operated under wet or
rainy conditions, or especially after using a h i g h ~
pressure spray water, perform the genera/lubrication.
Pivots: Lubricate with Motor Oil.
Clutch Lever
Front Brake Lever
Kick Pedal
Shift Pedal
Rear Brake Pedal
Drive Olain
PoInts: lubricate with Grease.
Outch Inner Cable Upper and lower Ends
Throttle Inner Cable Upper End
Swi ng Arm Pivot
Tie-Rod Pi V()(
Rocker Arm PiVOl:
Wheel Bearing
Steering Stem Bearing
Cables: lubricate with Motor Oil.
Outch Cable
Throttle Cable
Cab4e lubrication
1. Cable
,
2. Pressure Cable Luber. K56019-021
14-6 APPENDIX
Unit Conversion Table
.. ...... ... . .. . .. .. .. .. .. .. ...... . ... . . .... ... .. . ... .. .... . ..
Prefixes for Units;
Prefix Symbol Power
mega
kilo
centi
mini
micro
Units of Mass:
Kg
g
x
x
Units of Volume:
L x
L x
L x
L x
L x
L x
ml x
ml x
ml x
Units of Force:
N x
N x
kg x
kg x
M
k
c
m
"
Unit of Temperature:
x 1,000,000
x 1,000
x 0.01
x 0.001
x 0.000001
2. 205 - Ib
0.03527 = oz
0.2642
3
gallUS I
0.2200
-
gal limp)
1.057
3
qt IUS)
0.8799 = qt (i mp)
2. 113 = pint (US)
1.816
-
pint (imp)
0.03381
-
oz (US)
0.02816
-
oz limp)
0.06102
-
cu in
0. 1020 = kg
0.2248
-
Ib
9. 807
=
N
2.205
=
Ib
9 (OC + 40)
- 40 -
OF
5
Units of length:
km x 0. 6214 = mile
m x 3.281 = ft
mm x 0.03937 =
;n
Units of Torque:
Nm x 0. 1020
-
kg-m
Nm x 0. 7376 = ft lb
Nm x 8.851
=
in-Ib
kg-m x 9.807
-
Nm
kg-m x 7.233
-
ftlb
kg-m x 86.80
-
in-Ib
Units of Pressure:
kPa x 0 . 01020 =
kg/cm2
kPa x 0. 1450
-
psi
kPa x 0. 750 1
-
em Hg
kg/cm2 x 98.07 = kPa
kglc m
2
x 14. 22
=
psi
em Hg x 1.333
=
kPa
Units of Speed:
km/h x 0.6214
-
mph
Units of Power:
kW x 1. 360
-
PS
kW x 1. 341
3
HP
PS x 0. 7355
-
kW
PS x 0 . 9863
=
HP
5 (OF + 401
- 40
C
-
9
KX125
KX250
KX500
Motorcycle
Service Manual
Supplement
This supplement is designed to be used in conjunction with the '88 KX125/ KX250/ KX500 Motor-
cycle Service Manual (PI N 99924-1101-01). The maintenance and repair procedures described in this
supplement are only those that are unique to '89 KX 125/ KX250/ KX500 motorcycle. Most service
operations for these models remain identical to those described in the Base Service Manual.
Complete and proper servicing of the '89 KX125/ KX250/ KX500 motorcycle therefore requires this
Supplement and the Base Service Manual.
Table of Contents
General Information
Before Servicing ... ... . . .. . . . ... . ..
Model Identification .. ...... . .......
General Specification .......... . . .
Periodic Maintenance Chart ..... .... .
Torque and locking Agent . ..... ..... ..
Cable Routing . . .. . . ... . .... . .. , ..
Fuel System
Exploded View . . . .. . .. .. ... . . .. ...
Specifications ............... . ..... . .
Special Tools .. . .. .. ........... . ... .
Throttle Grip and Cable ............ . .. .
Throttle Grip Free Play Inspection . ...
Throttle Cable Adjustment .. . .. . .. . .
Throttle Cable Installation Notes . . . .. .
Throttle Cable Lubrication ......... .
Throttle Cable Inspect ion ..........
Carburetor .... . ........ . . .... .. . .
Idle Speed Inspection . ..... ... .. . .
Idle Speed Adjustment .... . , .. . .. . .
Service Fuel Level Inspection .. .. . .. . .
Service Fuel Level Adjustment ..... . .
Fuel System Clean ..... , . ........ .
Carburetor Removal. . ........ . ... .
Carburetor Installation Notes .... . ... .
Carburetor Disassembly ....... . ... .
Carburetor Assembly Notes .... ... . . .
Carburetor Cleaning . . . . .. .. .. . . ..
Carburetor Inspection ....... . . ...
Air Cleaner ..... ... ........... . .... .
Air Cleaner Housing Removal . . .. . .. .
Air Cleaner HOU$ing Installation
Notes .. . . . .
Air Cleaner Element Removal . ...... .
Air Cleaner Element Installation
Notes ..... . ...............
Air Cleaner Element Cleaning
and Inspection ..... . . . ....... .
Fuel Tank ....... . ............... .
Fuel Tank Removal .. . ... . .. . .. .. .
Fuel Tank Installation Notes . . . .... . .
Fuel Tap Removal . ..... . .. .. . . .. .

7
10
16
17
19
20
20

Fuel Tap Installation Notes ..... , .
Fuel Tap Inspection ... . . . ........
Fuel Tank Cap Inspection . .. .. .... ,
Fuel Tank and Tap Cleaning . . ... , .. .
Reed Valve .... . ....... . . ..... . , . ..
Reed Valve Removal ...... .. . . ...
Reed Valve Installation .... ... .... . .
Reed Valve Inspection .... . .. . .... .
Cooling System
Exploded View ... .. ..... . . .... . , ..
Specifications .. . ..... . ... . ..... ...
Special Tool . , . .. . ...... .. .. . ... .
Coolant ....... . .. . ...... . . ... ..
Coolant Inspection .............. .
Coolant Change ........... ... ... .
Air Bleeding . .................
Cooling System Pressure Testing . ....
Cooling System Flushing ... .. . .
Disassembly and Assembly Precautions , . . .. .
Water Pump . .. . .......... . .. .. . . .. .
Water Pump Cover Removal ... ... ..
Water Pump Cover Installation
Notes ............... . . . ... .
Impeller Removal ......... .... .. .
Impeller Installation . . . .... . .... . .
Impeller Inspection ....... ... . .
Water Pump Shaft Removal . . . . .. . . , .
Wetet' Pump Shaft Installation Notes ... .
au Seal Removal ...... . . .. .. . . . . .
air Seal Installation ......... .. ... .
Radiator ... . . ... .......... .. .. . . . .
Radiator Removal .. .... .. . . . .. . .
Radiator Installation ... ..... .
Radiator Inspection .... . ... . . ..
Radiator Cap Inspection ..... . . . ... .
Fillet' Neck Inspect ion ....... , .... .
Cooling Hoses . Breather Hose
Inspection ............ .. . . .
Cooling Hoses, Breather Hose
Installation Notes ....... ... . .
1

22

22

22

2
Engine Top End
Exploded View .. , .. ....... , . . .. 23
Specifications, ...... , .. , .......... 24
Special Tools ...................... .

Cylinder Head .................... 25
Cylinder Compression Measurement ... .

Cylinder Head Aemoval ... , .... .

Cvlinder Head Installation Notes ..... . 25
Cylinder Head Warp Inspection ...... .

Exhaust Valve (KIPS) ........ ......... . 25
Exhaust Valve Removal. . . . . . . . . . 25
Exhaust Valve Installation Notes ..... .
Cylinder, Piston .......... , ......... .
Cylinder Removal ............... .
Cylinder Installation Notes ....... , ..
Piston Removal ............ , .... .
Piston Installation Notes ........... .
Cylinder Wear Inspection . , ... . .... .
Pinoo Diameter Measurement ....... .
Piston/Cylinder Clearance .......... .
Piston Ring, Piston Ring
Groove Inspection ....... .. .... .
Piston Ring End Gap Inspection ...... .
Piston, Piston Pin, Connecting
Rod Wear Inspection ........... .
Muffler I Expansion Chamber, Silencer) ..... .
Expansion Chamber Removal ....... .
Expansion Chamber Installat ion
25
26

26

26

Notes. . . . . . . . . . . . . . . . . . . . .. 26
Silencer Wool Change ............. .

Engine Right Side
Exploded View. . . . . . . . . . . . . . . . . . . .. 27
Specifications. . . . . . . . . . . . . . . . . . . . .. 28
Special Tools ................... ...

Right Engine Cover .................. . 29
Right Engine Cover Removal ........ .

Right Engine Cover Installation
Notes .. ' ................... .

Riltlt Engine Cover Disassembly ...... .

Disassembly/Assembly Notes ...... . 29
Right Engine Cover Assembly
Notes ..................... .

Clutch ........................... 29
Clutch Adjustment .............. .
.
Clutch Removal/Disassembly ........ .

Clutch Installation Notes .......... . 29
Friction Plate Wear, Damage
Inspection ..................
Friction and Steel Plate
Warp Inspection .............. .
Clutch Spring Free Length
Measurement ................ .
Clutch Plate/Clut ch Housing
Clearance .... .... .. ......... .
Clutch Hub Spline Inspection ....... .
External Shift Mechanism ..............
External Shift Mechanism Removal. ... .
Installation Notes ............. .
Inspection ... , ............
Primary Gear ...................... .
Primary Gear Removal ............ .
Primary Gear Installation Notes ...... .
Kick Starter ....................... .
Kick Shaft Assembly Removal .......
Kick Shaft Assembly
Installation Notes ............. .
Kick Shaft Assembly
Disassembly/Assembly Notes ...... .
Kick Starter Idle Gear
Removal Notes ............... .
Kick Starter Idle Gear
Installation Notes .............

Engine Removal / Installation
Exploded View ... . ................. .
Engine Removal/ Installation ............
Engine Removal ..............
Engine Installation Notes .........
30

Engine Bottom End
ITransmission
Exploded View ......... . ...
Specifications ....................
Spedal Tools ......... . ...........
Transmission Oil ...................
Oil Level Inspection ..............
Oil Change ....................
Crankcase Splitting .......... ......
Crankcase Splitting .... ... . ... ... .
Crankcase Assembly ..............
30

31

31
Crankshaft. Connecting Rod ..... . ...... .
Crankshaft Removal .............. .
Crankshaft Installation Notes ........ .
Crankshaft Disassemblv Note ...... .
Crankshaft Assemblv Notes ........ .
Connecting Rod Big End
Radial Clearance .......... ..
Big End Seizure . ............ ....
Side Clearance ............ . .
31

Crankshaft Runout . . . . . . . . . . .. . .. 31
Crankshaft Alignment ............ :
Transmission . . . . . . . . . . . . . . . . . . . . . .. 31
Transmission Shaft Removal ........ .
Transmission Shaft Install ation
Notes ............... .
Transmission Shaft Disassemblv
Notes ..................... .
Transmission Shaft Assemblv
Notes ............. . ....... .
Shift Drum and Fork Installation
Notes ..................... .
Shift Fork Bending ..............
Shift Fork/Gear Groove Wear ....... .
Shift Fork Guide Pin/Shift
Drum Groove Wear ........ .
Gear Damage ............. .
Gear Dog/Gear Dog Hole Damage ..... .
Ball Bearing Wear ............... .
Wheels/ Tires
Exploded View ..... .
Specifications ........ , ...........
Special Tools ......................
Wheels .......................... .
Front Wheel Removal. ......... . .. .
Front Wheel Removal (other
than US and Canadian models) ..... .
Front Wheel Installation Notes ....... .
Front Wheel Installation Notes (other
than US and Canadian models) ..... .
Rear Wheel Removal ........ , .... .
Rear Wheel Installation Notes ....... .
Wheel Alignment Inspection ...... ..
Wheel Alignment Adjustment .... .
Wheel Inspection ............ .
Spoke Inspection ........ . ....... .
Rim Inspection .................
Axle Inspection. . . . . . . .... ...
Tires ......................... ..
Tire Removal .................. .
Tire Installation Notes ............ .
Tire Pressure Inspection/Adjustment ... .
Tire Inspecti on ................. .

32
32

33

33

33

Hub Bearing .................. .
Hub Bearing Removal Notes ........ .
Hub Bearing Installation Notes .. ... .. .
Hub Bearing Inspection
and Lubrication ........... .
Grease Seal Inspection
and Lubrication ..... , ........
Final Drive
ExplOded View ....................
Specifications ........ . .. .... . .....
Special Tools ..................... ,
Drive Chain .. , ....... . ............ .
Drive Chain Slack Inspection ........ .
Drive Chain Slack Adjustment ....... .
Wheel Alignment Inspection ........
Wheel Alignment Adjustment .......
Drive Chain WelK Inspection ....
Drive Chain Lubrication. , .........
Drive Chain Removal ..
Drive Olafn Installation Notes ....... .
Sprocket ......................... .
Engine Sprocket Removal .......... .
Engine Sprocket Installation Notes .... .
Rear Sprocket Removal ........... .
Rear Sprocket Installation Notes ..... .
Sprocket Wear Inspection .......... .
Sprocket Warp Inspection ..........
Brakes
Exploded View ..................
Specifications ........... .. .... ...
Special Tools ............ ... .. ...
Disc Brakes .............. .........
Brake Adjustment ................. .
Brake Lever/Pedal
Free Plav/Adjustment .......... .
Front Brake Lever Plav Adjustment ... .
Rear Brake Pedal Position
Adjuument ................. .
Rear Brake Pedal Plav Adjustment .... .
Calipers ........................ .
Caliper Removal ................ .
Caliper Installation Notes ..... ....
Caliper Disassemblv ..............
Caliper Assemblv Notes ........... .
Fluid Seal Damage .. . ............ .
Dust Seal and Cover Damage ........
Piston Cylinder Damage ......... . .
Caliper Holder Shaft Wear .......... .

34

35
35
36
36

36
36
36
36
37

3
4
Brake Pads .......... . ..........
Pad Removal ............... ...
Pad Installation ........... ...
Pad Inspection ..... , ........... .
Master Cylinder. .................... .
Front Master Cylinder Removal .. , ... .
Front Master Cylinder Installation
Notes .. . .................. .
Rear Mauer Cylinder RemOllal ....... .
Rear Master Cylinder Installation
Notes ..................... .
Front Master Cylinder Disassembly .... .
Rear Master Cylinder Disassembly . , .. .
Master Cylinder Assembly Notes . , . , ..
Mester Cylinder Inspection
(Visual Inspection) ............ .
Brake Disc ...................... .
Disc Inspection . ................ .
Brake Fluid ............. . .... . ..
Brake Fluid Requirement ....... ...
Brake Fluid Level Inspection ........ .
Brake Fluid Change ... . .......... .
Bleeding the Brake Line ........... .
Brake Hose ......................
Brake Hose Removal/Installation
Notes ............... . ..... .
Brake Hose Inspection ............ .
Suspension
Exploded View ...... . . .. .... . ....
Specifications ............ .........
Special Tools .......... . ........... .
Front Fork ........................ .
Front Fork Adjustment ........... .
Front Fork Removal . . ...........
Front Fork Installation Notes ....... .
Front Fork Disassembly (Oil Change)
(US and Canadian Models) ....... .
Front Fork Assembly (Oi l Change)
(US and Canadian Models) ....... .
Front Fork Disassembly (Oil change)
(Other than US and Canadian
Models) .............. . .... .
Front Fork Assembly (Oil Change)
(Other than US Canadian Models) . . .
Inner Tube Inspection ...... .. ... . .
Guide Bush Inspect ion ............ .
Oil Seal and Outer Tube Seal
Inspection .................. .
Spring Tension ................
37
37
37
37

37

37

38
39
40
40
40

44
44
44
46

Rear Suspension (Unitrak) .... . ....... . .
Rear Shock Absorber .... . ......... .
Shock Damping Adjustment ........ .
Rear Shock Absorber Removal. ...... .
Rear Shock Absorber Installation
Notes ..................... .
Rear Shock Absorber Spring
Replacement ................ .
Rear Shock Absorber Disassembly
(Oil Olange) ................. .
Swing Arm ...................... .
Swing Arm Removal .............
Swing Arm Installation Notes , .....
Tie-rod, Rocker Arm ..............
Tie-rod Removal ..... , .........
Tie-rod InstaUation Notes ..........
Rocker Arm Remova!. ............ .
Rocker Arm Installation Notes ..... ..
Unitrak Maintenance ....... , ....... . .
Sleeve ..... . ................. .
Rocker Arm .......... . .......
Mounting Boh Bend ..... . . ..
Steering
Exploded View ........ , . . ....
Special Tools ............. . ...... .
Steering Adjustment .................
Steering Inspection ... . ........ .
Steering Adjustment . . ... .. .. , ..
Steering Removal/ Installation ........... .
Steering Stem Removal. ........... .
Steering Stem Installation Notes ...... .
Steering Stem Race Removal .... .
Steering Stem Race Installation Notes .. .
Steering Maintenance ........... . ..... .
Steering Stem Bearing lubrication .... .
Bearing Wear, Damage ............ .
Steering Stem Warp ... , ......... . .
Electrical System
Exploded View ... . ..............
Wiring Diagram .. , ..... ...........
Specifications .......... . .........
SpeCial Tools ............. . . ...
Precauti ons ...... .. . . ...
48
48

48

49

49
50
51

Electrical Wiring .... . . . ...........
Wiring Inspection ........ .....
Ignition Timing . .... . ........... ...
Ignition Timing Adjustment ..... ..
FI,vwheel Magneto ................... .
Flywheel Magneto Removal. ...... . . .
Flywheel Magneto Installation ..... , ..
Flywheel Magneto Inspection ....... .
Ignition System .... ........... . ..... .
Safety Instructions ..............
Ignition Coit Removal ........ .... .
Ignition Coil Installation ........... .
Ignition Coil Inspection ...........
Spark Plug Cleaning and Inspection .... .
Spark Plug Gap Inspection ......... .
COl Unit Inspection, . , ........... .
Stator Coil Inspection ............

51

51
51
51
Appendix
Troubleshooting Guide. , ....... . ....
General Lubrication ....... , , . , . , , .
Unit Conversion Table , . , .... , . .....
: For the KX125-G' , maintenance work is the same as for the KX 125-F 1.
For the KX250-G 1, maintenance work is the same as for-the KX250-F 1.
For the KX500-E 1, maintenance work is the same as for the KX5000 1.
A ampere!sl Ib Pound(sl
ABCO after bottom dead center m meter(sl
AC alternating current min minute(sl
ATOC after top dead center N newton(sl
BBOC before bottom dead center Pa Pascal(sl
BOC bottom dead center PS horsepower
BTDC before top dead center psi pound(sl per square inch
C
degree(sl Celcius r revolution
DC direct current rpm revolution(sl per minute
F farad,s) TOC top dead center
of
degree(sl Fahrenheit TIA total indicator reading
ft foot . feet V volt!sl
9
gram(s) W watt(sl
h houris) II ohm(s)
L liter(s)
5

6
WARNING
CONTAINS
AS8ESTOS
IlbIIIO.
I. danlll'ou,
10
Follow Hft.ty
inmuct ......
(U. K. model only)
This warning may apply to any of the follow-
ing components or any assembly containing
one or more of these components:-
Brake Shoes or Pads
Gaskets
Insulators
SAFETY INSTRUCTIONS
- Operate if possible out of doors or in a well
ventilated place.
- Preferably 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.
-I f possible. dampen before cutting or drilling.
- Dampen dust and place it in properly closed
receptacle and dispose of it safely.
Except for the following description, the maintenance work
for the KX125-G 1 is the same as for the KX 125-F 1,
for the KX250-G 1 is the same as for the KX250-F 1,
for the KX500El is the same as for the KX500-D1.
General Information
............................................................................
KX125-Gl (US and Canadian Model) Right Side View
KX125-Gl IOther than US and Canadian Model) Right Side View
7
8
KX250-G 1 (US and Canadian Model) Right Si de View
KX250-Gl (Other than US and Canadian Model) Right Side View
9
KX500E1 (US and Canadian Model) Right Side View
KX500E1 (Other than US and Canadian Model) Right Side View
10
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight: Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark Plug
Port timing: Inlet
Scavenging
Exhaust
Lu brication system
Drive Train:
Type
A eduction ratio
Clutch type
Open
Close
Open
Close
Open
Close
KX12SG1
2145 mm
815 mm
1 170 mm
1460mm
3BOmm
935mm
B6.S kg
4S.S kg
4B.S kg
B.6 L
2-stroke, single cylinder, crankcase reed valve
Liquid-cooled
56.0 )( 50.6 mm
124 mL
7.B: 1 (High speed). B.S : 1 (Low speed)
26.B kW (36.S PSI @11 SOO rl min (rpm)
24.S Nm (2.S kgm,l B.l ftlb) @9,SOO rlmin (rpm)
Primary kick
CDI (D.C.I.S.)
13.Bo BTDC@ll 000 rl min (rpm)
NGK Bl0EG @ NGK BR10EG
Full open
61
0
BBDC
61
0
ABDC
90
0
BBDC (High speed). 9S.S
o
BBDC (Low speed)
90
0
ABDC (High speed). 9S.S
o
ABDC (Low speed)
Petrol mix (32: 1)
Gear
3.S00 (63/ 18)
Wet, multi disc
Items
Transmission: Type
Gear ratios:
1st
KX125G1
6speed, constant mesh, return shift
2.142 (30/ 14)
2nd 1.714(24/ 14)
3rd
4th
5th
6th
Reduction ratio
1.400 (28/ 20)
1.181 (26/ 22)
1.041 (25124)
0.920 (23125)
Chain drive
3.916(47/ 12)
12.611 @Top gear
SE class
Overall drive ratio
Transmi ssion oil:
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire :
Rear tire:
Front suspension:
Rear suspension:
Grade
Viscosity
Capacity
Make/Type
Size
Make/Type
Size
Type
Wheel travel
Type
Wheel travel
SAE lOW30 or lOW40
0.7 L
45
0
to either side
26.5
0
l09mm, @ 116mm
DUNLDP K490 DUNLOP K990, Tube type
80/ 1oo2151M
DUNLOP K595 OUNLOP K990, Tube type
loo/ 90-1957M lID l00/ loo1859M
Telescopic fork (Air fork)
300mm
Swing arm (Uni-trak)
330mm
Brake type: Front and Rear Single disc
Effective disc diameter: Front 220mm
Rear 190mm
: Canadian model
@ : European model
I(j) : U.K. model
@ : U.S. model
11
12
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight: Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark Plug
Port timing: Inlet
Scavenging
Exhaust
Lubrication system
Drive Train:
Type
Reduction ratio
Clutch type
Open
Close
Open
Close
Open
Close
KX250G1
2190 mm
815 mm
1205 mm
1490 mm
370mm
950mm
96.5 kg
50 kg
52 kg
8.5 L
Liquid-cooled
67.4 x 70.0 mrn
249 mL
9.8 : 1 IHigh speed), 11.3 : 1 (Low speed)
9.4 : 1 (High speed). 10.8 (Low speed)
38.2 kW (52 PSI @8 000 rlmin (rpm)
47. 1 Nm (4.8 kgm. 34.7 ft lb) @7 500 rim in (rpm)
Primary kick
COl (D.C.I.S.)
14
0
BTDC @6 000 r/ min (rpm)
NGK 89EG <ill NGK 8R9EG
Full open
60.5' 88DC
60.5' A8DC
81 .5' 88DC (High speed), 92' 88DC (Low speed)
81.5' A8DC (High speed). 92' ABDC (Low speed)
Petrol mix (32 : 1)
Gear
2.7S0ISS/20}
Wet, multi disc
Items
Transmission: Type
Gear ratios:
1st
2nd
KX250G1
2. 133132/ 15)
1.687127/ 16)
3rd 1.388 125/ 18)
4th 1.136 (25122)
Reduction ratio
5th 1.000 (24124)
Chain drive
3.357147/ 14)
9.232 @Top gear
SE class
Overall drive ratio
Transmission oil :
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire:
Rear tire :
Front suspension:
Rear suspension:
Brake type:
Grade
Viscosity
Capacity
Make/Type
Size
Make(Type
Size
Type
Wheel travel
Type
Wheel travel
Front and Rear
SAE 1OW30 or lOW40
0.8 L
45t o either side
27'
112mm @ 119mm
DUNLOP K490 lID DUNLOP K990. Tube type
80/ 100-2151M
DUNLOP K595 lID DUNLOP K990. Tube type
100/ 100-1864M @110/ 9O-1962M
300mm
Swing arm (Unitrak)
330mm
Single disc
Rear 190 mm
: Canadian model
: European model
@ : U.K. model
@: U.S. model
13
14
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight: Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark Plug
Port timing: Inlet
Scavenging
Exhaust
Lubrication system
Drive Train:
Type
Reduction ratio
Clutch type
Transmission: Type
Gear ratios:
Open
Close
Open
Close
Open
Close
1st
2nd
KX500E1
2190 mm
815 mm
1205 mm
1490 mm
370mm
950mm
100 kg
52 kg
54 kg
9.9 L
Liquid-cooled
86.0 x 86.0 mm
499mL
6.8: 1 (High speed), 7.7: 1 (Low speed)
46.7 kW (63.5 PSI @7 000 rl min (rpm)
65.7 Nm (6.7 kgm, 48.5 ftlb) @6oo0r/min (rpm)
Primary kick
COl
17
0
BTDC @6 000 r/ min (rpm)
NGK 88EG @ NGK BR8EG
Full open
60' B8DC
60' ABDC
B3.5' BBDC (High speed), 93.5' BBDC (Low speed)
83.5' ABDC (High speed), 93.5' ABDC (Low speed)
Petrol mix (32 : 1)
Gear
2.538 (66/26)
Wet, multi disc
5speed, constant mesh, return shift
2.000 (32/ 16)
1.450 (29/20)
3rd 1.181 (26/22)
4th 0.954 (21/22)
5th 0.791 (19/ 24)
Items KX500-El
Final drive system: Type Chain drive
Reduction ratio 3.357 (47/ 14)
Overall drive ratio 6.746 @Top gear
Transmission oil : Grade SE class
Viscosity SAE 101'130 or 10W40
Capacity 0.8 L
Frame :
Type Tubular, single down tube
Steering angle 45
0
to either side
Caster (rake angle) 27'
Trail 112mm @ 119mm
Front tire: Make/Type 8RIDGESTONE M845
DUNLOP K990, Tube type
Size 80/ 1002151M
Rear tire: Make/ Type 8RIDGESTONE M845
DUNLOP K990, Tube type
Size 110/ 100-1864M @ 110/ 90-1962M
120/ 100-18 68M
Front suspension: Type Telescopic fork (Air fork)
Wheel travel 300mm
Rear suspension: Type Swing arm (Unltrak)
Wheel travel 330mm
Brake type: Front and Rear Single disc
Rear 190mm
: Canadian model
: European model
@ : U.K. model
@ : U.S. model
15
16
Periodic Maintenance Chart
FREQUENCY
Each Every Every Every As
OPERATION
Clutch-adjust

Clutch and friction plates-check t

R
Throttl e cable-adjust


R

Air cleaner element replace Damaged
Carburetor inspect/adjust

w
Transmission oil --change

z Piston and piston ring--clean/check t

R
'"
Cylinder head. cylinder and exhaust
z
valves- inspect

w
Muffler-clean/ check t

Silencer wool--thange

Small end bearing-check t

R
Kick pedal and shift pedal --clean

Exhaust pipe O-ring--replace


Coolant-check t

R
..... Radiator hoses, connections-check t


Brake wear--check t

Brake fluid level--check t

"'Brake fluid- change Everv 2 vears
Every 2 years
seal--replace
Brake caliper piston seal and dust seal--replace Every 2 years
Brake hose and pipe--replace Every 4 years
Spoke tlg tness and rim runout-check t

Drive chain--adjust

Drive chain- lubricate

Drive chain wear--check t

en
Chain slipper and guide--replace Damaged
-

Front fork - inspect/clean
I I I I

:I: Front fork 1 st time after 2 races, then every 5 races
u
Nuts, bolts, fasteners-check t

I
Fuel hose- replace Every 4 ears
Fuel svstem--clean

Steering play-check t

Steering stem bearing--grease

Rear sprocket-check t

General lubrication- perform

Wheel bearing--grease

Swing arm and Uni-trak linkage pivots-check t

Swing arm and Uni-trak linkage pivots-grease

Rear shock oil--replace 1 st time after 2 races, then every 5 races
t Replace, add, adjust or torque if necessary. R : Replace
Should be serviced by referring to the Service Manual.
17
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may become damaged or fall out. possibly resulting in damage to the motor-
cycle and injury to the rider. A bolt or nut which 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 nonpermanent 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.
Letter used in the " Remarks" column mean:
L : Apply a non-permanent locking agent to the threads.
LG : Apply liquid gasket t o the threads.
S : Tighten the fasteners following the specified sequence.
Fastener
Nm
Fuel System:
Rear Frame Mounting Bolts
(Upper) 34
(Lower) 25
Cool ing System:
Water Pump Impell er Bolt (KX500) 6.9
Engine Top End:
Main Exhaust Valve Cover Bolts 9.8
Engine Right Side:
Clutch Hub Nut (KX125) 88
Engine Removal/Installation:
Engine Mounting Nut (10 mm Dia.) 34
Engine Mounting Bracket Nut
(8 mm Dia.) 26
Engine Mounting Bracket Bolt
(8 mm Dia,) 26
Wheel/Tires:
Front Axle Nut* 54
Front Axle** 54
Brakes:
Brake Pad Bolts 18
Caliper Bl eed Valve 5.4
Brake Pipe Joint** 18
Torque
Remarks
kgm ftlb
3.5 25
2.6 19.0
0.70 61 in-Ib
1.0 87 inlb
9.0 65
3.5 25
2.7 19.5
2.7 19.5
5.5 40
5.5 40
1.8 13.0
0.55 48 inlb
1.8 13.0
18
Fastener
Torque
Remarks
N-m kg-m ft-lb
Suspension
Front Fork Top Bolts 27 2.8 20
Front Fork Top Bolts" 29 3.0 22
Front Fork Clamp Bolts* 21 2.1 15.0
Front Fork Clamp Bolts"
(Upper) 21 2.1 15.0
(Lower) 20 2.0 14.5
Front Axle Clamp Nuts B.B 0.90 78 in-Ib
Push Rod Stopper"
26 2.7 19.5
Front Fork Protector Bolts" B.B 0.90 78 in-Ib
Front Fork Cylinder Valve Assembly 54 5.5 40 L
Rear Shock Absorber Mounting Bolts 34 3.5 25
Tie-Rod Mounting Nuts Bl B.3 60
Rocker Arm Nut Bl B.3 60
Steering:
Handlebar Holder Mounting Bolts 25 2.5 lB
: US and Canadian Models
.. : Other than US and Canadian Models
Cable Routing
KX125:
1. Clutch Cable
2. Clamp
3. Strap
4. Radiator Breather Hose
KX125,250:
1
1. COl Unit
2. Throttle Cable
3. Engine Stop
Switch l ead
4. Clamp
19
20
Fuel System
Exploded Vi ew
Specifications
KX125:
Item
Make/ type
Main jet
Throttle valve cutaway
Jet needle
Jet needle clip position
Slow jet
Air screw
Service fuel level
Bore center
Float height
T1 : 34 N-m (3.5 kg-m, 25 ftlb)
T2: 25 N'm (2.6 kg-m. 19.0 ft-Ib)
Standard
KEIHIN PWK35
155
6
R2067N
4th groove from the top
52
1 % (turns out)
1.0 1 mm
32 mrn
16 1 mrn
Service Limit
- -_.
---
---
---
---
---
---
---
---
---
21
KX250:
Make/type KEIHIN PWK38
-- -
Main jet 172 ---
Throttle valve cutaway 7 - --
Jet needle R 1368J
---
Jet needle clip position 4th groove from the top ---
Slow jet 55
---
Air screw 1% (turns out) ---
Service fuel level 1.0 lmm
- - -
Bore center 34mm
---
Float height 16 1 mm ---
KX500:
Make/ type KEIHIN PWK39 ---
Main jet 170 ---
Throttle valve cutaway 7
---
Jet needle R1369N ---
Jet needle clip position 4th groove from the top
---
Slow jet 60
---
Air Screw 1% (turns out) ---
Service fuel level 1.0 lmm ---
Bore center 34 mm - --
Float height 16 1 mm
---
22
Reed Valve
Reed Valve Installation
Install the reed valve holder as shown.
Upward
)D
D
a a
aup a
a a
a a
D
a a
a a
Downward KX12S
KX250
a a
a
aD-a
KX500
1. Projection
j
Cooling System
Exploded View
KX500:
T1 : 6,9 N-m (0.70 kg.m, 61 in.lb)
23
Engine Top End
Exploded View
............................................................................
KX125:
o
KX25Q:
""-
--
24
KX500:

T1: 9,8 N.m (1.0 kg-m, 87 in-lb)
Specifications
KX125:
Cylinder, Piston:
Cylinder inside diameter 56.020 - 56.035 mm 56.10 mm
Piston/cylinder clearance 0.071 - 0.081 mm
---
Piston ring groove width: Top 0.830 - 0.850 mm 0.93 mm
Second 0.815 - 0.835 mm 0.92 mm
KX250:
Cylinder. Piston:
Piston/cylinder clearance 0.054 - 0.064 mm ---
.............................................................................
Cylinder Head
.............................................................................
Cylinder Head Installation Notes
_For KX500El model, install the cylinder head gasket
as shown.
~ 0
1

4
1
1. Metal Section
2. Short
3. long
4. Short side faces upward.
Exhaust Valve (KIPS)
e For KX500.fl model, removal is the same as for the
KX250-G1.
25
Exhaust Valve Installation Notes
- For all models, be careful not to mix up the right and
left exhaust valves. The right valve has an identifing
groove.
1. Groove
eFor KX12S-Gl model, install the main exhaust valve so
that the stepped side faces upward.
1. Groove
2. Spacer
3. Stepped side faces upward.
5. Cover
6.0.,.ing
7. Main Exhaust Valve Holder
8. Spring Washer
1
2
3
e For KX500El model, installation is the same as for
the KX250-G1, except for the tightening torque of the
left plug on the cylinder.
Tightening Torque
20 N-m (2.0 kg.m. 14.5 ft.fb)
26
........................... .......................................... .. ... ..
Cylinder, Piston
.............................................................................
e Measure the outside diameter of the piston 16 mm
(KX12S), 20.5 mrn (KX250) or 26.1 mm (KX500) up
from the bottom of the piston at a right angle to the
direction of the piston pin.
*I f the measurement is under the service limit, replace
the piston.
Piston Diameter
KX12S:
Standard: 55.940 - 55.955 mm
Service limit: 55.79 mm
KX250:
Standard: 67.341 - 67.356mm
Service limit : 67.23 mm
KX500:
Standard: 85.910 - 85,925 mm
Senoice Limit: 85.80 mm
/
'--
~ o o / /
A : KX125 - 16 mm
KX2S0 - 20.S mm
KXSOO - 26.1 mm
.................................................... ................... ......
Muffler (Expansion Chamber, Sik!ncer)
.............................................................................
Expansion Chamber Installation
e Apply molybdenum disulfide grease to the Oring on
the exhaust port.
27
Engine Right Side
Exploded View
KX125:
T1 : 88 N-m (9.0 kg..,.. , 65 ft.lb)
KX25Q:
T1 : 98 N-m (10 kg..,.. , 60 ft-lb)
28
KX500:
Specifications
Clutch:
Steel plate thickness 1.41 - 1.59mm 1.31 mm
Friction plate tang width: KX125 11 .8 - 12.0mm 11.3 mm
KX250, KX500 13.6 - 13.8 mm 13. 1 mm
..................
R' .......
Ight Engine Co ....... ........................ .
... ... ver ....... .
... .............. . ........ ..
Exhaust Ad ............. ....... .......... ................. .
A
vancer A ......
ssembl N ssembly D'
oTh y otes lSassembly/
e exhaust adva
lowing parts. neef assembly
KX125:
KX250:
KX500:
9 8 9
@
1. Pi ns
2. Rod
3. Guide
4. O-ring
5. Steel Balls
6. Holder
consists of th e fol-
sNecdle Bcaring
. pacer
9. Collar
10, Spring
,1. Gear
. ......... .
c
.. .. lutch .... .. .... .... .
.......... .." -, .. ,- .........
29
. ..... .
....... ..... ..... .......... .........
Clutch InstaJla . . .. .. ... ....... ..... .... ... ..... .... .... .
e For KX12S.{;/lon Notes
the friction I the insid d'
with th' ato " '",or than ;h "m'''' of on, of
concave side; and spring seat as She others. Install it
ust be faced Inside. own below. Spring
1. The inside d
3
2. Spring Seat lameter is larger than oth
. Spring ers.
e For KX250-Gl
between the model the
th, "hiei,. n" and th' ei,,':::'th'd wash"
oothed washer I the maimenan wheel is not . ce work for the
30
Exploded View
KX125:
Engine Bottom
End/ Transmission
Exploded View
KX125:
KX250:
KX250. KX500:
T1 : 34 N-m (3.5 kg-m, 25 ft-Ib)
T2: 26 N-m (2.7 kg-m, 19.5 ft-Ibl
Crankcase Splitting
Crankcase Assembly
eFor KX500El model, install the bearing for the drive
shaft into the left crankcase half so that stepped side
faces inside.
e Apply non.permanent lod;ing agent to the threads of
the drive shaft bearing holder screws.
1. Stepped Side
2. Holders
3. Apply non-permanent locking agent.
Crankshaft, Connecting Rod
Crankshaft Runout
e Set the crankshaft ifl a flywheel alignment jig or on V
blocks, and place a dial gauge against the points indi-
cated.
eTurn the crankshafl slowly. The maximum difference
in gauge readings is the runout.
Cranksnaft Runout
Standard : Not more than 0 ,03 mm
Service Limit : IKX125, 250) 0.05 mm
(KX500) 0.10 mm
Crankshaft Runout
Turn the crankshaft
slowly.
A : KX125 - 8 mm
KX250 - 8.5 mm
KX500 - 9 mm
31
. ....... " .. " .. ................................. , ......... .. ..... .. ........ .
Transmission
.... ....... .......................... .. .. .. ... ... ............................
Output Shaft Gears
KX125:
1, 2nd gear (24T; dog recesses face right)
2. 5th gear (2ST; fork groove goes to the right side of
the gear teeth)
4. 4th gear (26T; dog recesses face ri ght)
5. 6th gear (25T; fork groove goes to the left side of
the gear teeth)
6. lst gear (23T; plain side faces right)
7. Collar
32
Wheels/ Tires
Exploded View
.................................. ................ .. ... ....... .......... .....
Specifications
Item
Tires:
(KX125,250)
Front : Size
Make, type
Aear: Size: KX125
KX250
Make, type
(KX5OO)
Frpnt: Size
Make, type
Rear: Size
Make, type
Size
Make, Type
@Size
@ Make, Type
: Canadian model
: European model
@ : USmodel
T1 : 54 N-m (5.5 kgm, 40 ftl bl
T2: 9.8 N'm (1.0 kgm, 87 inlbl
T3: 26 Nm (2.7 kg-m, 19.5 ftlb)
T4: 98 Nm (10 kg-m, 72 ftlb)
Standard Service Limit'
80/ 1OO-2151M
---
DUN LDP K490 DUN LDP K990 ---
1OO/ 1oo-1859M @ 100/ 90-19 57M - - -
110/ 1oo-1864M @ 110/ 90-1962M
- - -
DUNLDP K595 DUNLOP K990
---
80/ 100-2151M
- --
BRIDGESTONE M845, DUNLOP K990
- - -
110/ 1oo-1864M - --
BR IDGESTONE M848 ---
120/ 1OO-1B 68M ---
DUNLOP K990 ---
110/ 90-1962M ---
BRIDGESTONE M848
---
Wheels
Front Wheel Removal
(other than US and Canadian models)
e Place a stand.or block under the motorcycle so that the
front wheel is raised off the groond.
e Loosen the axle clamp nuts on the right side of the
wheel.
e Loosen the a)::le.
A. Axle Clamp Nuts B. Axle
e Remove the axle clamp nuts and the axle clamp.
e Unscrew the axle from LH front fork and pull it off
the wheel.
eRemove the wheel, coliar, and caps.
A. Collar B. Caps
0 00 not lay the wheel on the ground with the di sc
facing down. This can damage or warp the disc. Place
blocks under the wheel $0 the. disc does not touch the
ground.
33
elnsert a wood wedge between the disc brake pads. This
position, should the brake lever be squeezed acciden-
tally.
Front Whee/Installation Notes
(other than US and Canadian models)
- Fit the projection on the cap to the groove on the
collar and axle.
A. Projection B. Cap
A
A. Groove
e Tighten the axle to the specified torque.
Tightening Torque
54 Nm (5.5 kg-m, 40 ft-Ib)
e The arrow mark on the axle clamp must point upward.
34
A. Arrow Mark
e Tighten the upper clamp nuts first, and tighten the
lower clamp nuts to the specified torque.
Tightening Torque
8.8 N-m (0.9 kg-m, 78 inlb)
Final Drive
Specifications
Item
Drive Chain :
Make
Type: KX125
KX250
Length: KX125
KX250, KX500
20-link length
_ Check the front brake for weak braking power and
brake drag.
I WARNING'
0 00 not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are ~ g i n s t the disc. The brake will not
function on the first application of the lever if this it
not done.
Daido
---
D.I.D 520 D5-6 ---
D.I.D 520 D5-5 - --
112 Link - - -
114 Link - --
317.5 mm 314mm
Brakes
Exploded View
.... .......................................... ...............................
I
I
I
T2
Specifications
Disc Brake:
Item
Brake Pads;
Pad li ning thickness: Front
Rear
Brake Discs:
Disc thickness: Front
T1 : 5.9 N-m (0.6 kg-m. 52 i n ~ b
T2 : 25 N-m (2.5 kg-m, 18.0 f t ~ b
T3 : 8.8 N-m 10.9 kg-m, 78 in",b)
T4 : 18 N-m 11 .8 kg-m, 13.0 ft-IM
T5 : 5.4 Nm (0.55 kg.m, 48 in-Ibl
T6: 18 N-m 11 .8 kg-m, 13 ft.lb)
T1 : 9.8 N-m 11 .0 kg-m. 87 inlb)
: US and Canadian Model
35
.. : Other than US and Canadian Model.
4.5mm 1 mm
4.7 mm 1 mm
2.85 - 3.15 mm 2.5mm
36
Special Tool
The following special tool is added for brake fluid
change.
Oil Syringe: 57001-1290
Disc Brakes
Calipers :
Caliper Removal
- Loosen the brake pad bolts before the caliper removal
if the caliper is to be disassembled.
aFor the front caliper of other than US and Canadian
models, remove the brake hose clamp bolt and brake
lever, and free the brake hose.
A. Clamp Bolt D. Brake Pad Bolts
B. Brake Pipe E. Collar
C. Caliper Mounting Bolts
- Disconnect the brake pipe joint, and remove the brake
pipe.
A. Brake Pipe Joint B. Brake Pipe
Caliper Installation Notes
aTi ghten the brake pad bolts to the specified torque if it
was removed.
Tightening Torque
18 N-m 11 ,8 kg-m, 13.0 ft -Ib)
OCheck that brake pipe does not touch to the other
parts.
Caliper Disassembly
Loosen the brake pad bolts before caliper removal, and
remove the brake pad bolts before the pad removal.
A. Brake Pad Bolts
e For the front caliper, there are two pistons in the
caliper. Holding the one piston in place, lightly apply
compressed air to where the brake line fits into the
caliper. Another piston comes out by air pressure.
Temporarily install the removed piston. Take care that
not to push it so far. Remove the remaining piston by
lightly applying compressed air to where the brake line
fits into the caliper.
I WARNING'
o To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com
preued air into the caliper, the piston may crush your
hand or fingers.
NOTE
OW/len removing the pistons with brake fluid pressure,
remporsrily install the piston which is removed first to
remove the remaining piston as described above.
- Tighten the brake pad bolts to the specified torque.
Tightening Torque
18 N-m 0 .8 kg-m, 13.0ft-lb)
Brake Pads:
Pad Removal
e For the front caliper of other than US and Canadian
models, remove the brake hose clamp bolt before the
caliper removal (see Caliper Removal).
_Loosen the brake pad bolts before the cal iper removal.
A. Brake Pad Bolts
37
Pad Installation
_Tighten the brake pad bolts to the speCified torque.
Tightening Torque
18 N-m 11 .8 kg-m, 13.0 ft.lb)
Pad Inspection
- Check the lining thickness and condition of the pads in
each caliper.
*If either pad is damaged, replace both pads in the
caliper as aset.
*If the lining thickness of either pad is less than the
"t.
1. Service Limit
Pad Lining Thickness (mm)
Front Rear
Standard 4.5 4.7
Service Limit 1 1
Brake Fluid:
Brake Fluid Change
Using the oil syringe (special tool), pump out the brake
fluid.
A.Oil Syringe: 57001-1290
38
Suspension
............................................... ..............................
Exploded View
........... ................................. ............ .....................
,
,
, 0

:cwJ 0
t g \j :
, ,
L ____ _ _ _ ______ __ _ _ __ _ _ ___ ...J
...-----jn

r - - - - - - - - - - - - - - - - - - --,
I I"--, ,

I
f
o
!iii

o
: 0
,
I
I" ria
, "'1>/
I
I
I

d
..
'"
..
I
L __ _ _ _________ _ _ __ ___ _ __ _ J
T1 : 21 Nm (2.1 kgom, 15.0 ft-lb)
T2 : 20 N-m 12.0 kg.m. 14.6
T3 : 29 N-m 13.0 kg-m, 22 ft-lbl
T4 : 26 Nm 12.1 kg.m, 19.5 ft..jb)
1'5 : 8.8 N-m (0.90 kg-m, 78 in.tb)
T8: 54 N-m (5.5 kg..m, 40 ft-lb)
T7: 81 N' m (8.3 kg-m, 60 ft-lb)
T8 : 34 Nm (3.5 kg-m, 25 ft-lb)
T9 : 27 N-m 12.8 kg-m, 20 ft -Ib)
: US and Canadian Models
.. : Other thin US and Canadian Modell
39
Specifications
Front Fork:
Air pressure Atmospheric pressure ---
Oil viscosity KAY ABA 01 - --
Oil capacity
US and Canadian Models 605 4mL - - -
Other than US and Canadian Models 425 4 mL ---
Oil level (fully compressed, spring removed) (adjustable range)
US and Canadian Models 150 2 mm 120-1BOmm
Other than US and Canadian Models 115 2 mm BO - 140mm
Fork spring free length
US and Canadian Models 560mm 549mm
Other than US and Canadian Models 505mm 495mm
Rear Suspension:
Spring preload:
adjusting nut position from the center
of the upper mounting hole
KX125 116 mm 106 - 126 mrn
KX250, KX500 114 mm 104 - 124 mm
40
............ .. .. .............................. ...............................
Special Tools
...................... .. ..................... ...... ....... ........... .. ......
Spring Holder: 570011286
Oil Cylinge : 57001-1290
Front Fork Cylinder Holder : 57001 -1287
Front Fork Oil Seal Drill'8r : 57001-1288
Push Rod Puller : 57001 -1289
Jack Stand : 570011238
Front Fork
Front Fork Adjust ment
Air Pressure Adjustment
_ Use a jack stand (special tool: 570011238) under the
frame, stabilize t he motorcycl e .
Pl ace a stand or block under the engi ne 50 that the
- Unscrew the air releasing screw, and release the exces-
sive air.
A. Air Releasing Screw
Oil Level Adjustment
_ Use jack stand (special tool: 57001-1238) under the
frame, stabilize the motorcycle .
Place a stand or block under the engine so that the
front whee l is raised off the ground.
I WARNING I
o Lift the front wheel before unscrewing both top bolts,
orthe front fork tubes compress all the way and
hazard can occur.
_ Remove the following.
Number Plate
Handlebar Clamp
Handlebar
Front Fork Top Bolt
A. Front Fork Top Bolt
Front Fender
Brake Hose Clamp
(other than US and Canadian Models)
Front Caliper
A. Caliper C. Brake Hose Clamp
B. Mounting Bolts
Front Fork Protector
(other than US and Canadian Models)
41
A. Front Fork Protector B. Mounting Bolts
e Slowly compress front fork fully with pushing up the
inner tube lower end (for other than US and Canadian
models, touch a stepped portion of the inner tube to
the outer tube dust cover lower end), and place a stand
or other suitable means under the front wheeL
(US and Canadian Models)
(Other than US and Canadian Models)
A. Inner Tube C. Dust Cover
B. Outer Tube
42
OAt this ti me, do not hit the front brake pipe and other
parts .
Pulling down the fork spring and insert the spring
holder (special tool) under the push rod nut.
A. Spring C. Spring Holder: 570011286
B. Top Bolt
_ Unscrew the both right and left top bolts.
Remove the spring holder, and remove the spring.
A. Top Plug C. Spring
B. C-ring
e Remove the push rod nut, and remove the spring guide
(other than US and Canadian Models).
A. Pum Rod Nut B. Spring Guide
e Using the oil syli nge (special tool), measure the i ~
tance from the top of the fork tube to the oil level.
Standard Oil Level:
(US and Canadi an Models)
148 - 152 mm
113 - 117 mm
Adjustabl e Range:
110 - 180 mm
80 - 140 mm
A. Oil Syringe: 57001-1290
e Adj ust the oil level as requi red within the adjustable
range using one of the foll owing oils.
Recommended Oil
KAYABA 01
el nstall t he spring guides and push rod nuts at the push
rods (other t han US and Canadian Models).
o lnsta ll the spring guide so that the hole comes lower
side.
A. Push Rod Nut C. Hole
B. Spring Guide
e Put the fork spring in both fork tubes.
e Screw in the push rod puller (special tool) onto the
push rod.
A. Push Rod B. Push Rod Puller : 57001-1289
ePull up the push rod.
ePulling down the fork spring and insert the spring
holder (specia l tool) under the push rod nut.
43
A. Push Rod C. Spri ng Holder: 570011286
B. Push Rod Nut
e Remove the push rod pull er.
e Check the O-ring of t he top bolts for damage. If
necessary, replace them.
e lnstall the top bolton the push rod.
A. Top Bolt c. a Ring
B. Push Rod
e Remove t he spri ng holder.
el nstall the another top bolt on t he other push rod.
elnstall the top bolts on t he top of the fork tubes and
t ighten them to the specified torque.
Tightening Torque
(US end Canadian Modeh)
27 Nm (2.B kg-m, 20 ft-lb)
(Upper)
27 Nm (2.8 kg.fJI, 20 ft-lb)
(Lowar)
20 N m (2.0 kg-m, 14.5 ft-lb)
el nstall the parts removed.
44
_ When f"cmoving the top bolt, insert the spring holder
(special tool) under the push rod nut.
A. Top Bolt C. Spring Seat
B. Spring Holder : 57001-1286
e After pouring in the fork oil specified, perform the
following.
oScrew in the push rod puller (special tool) onto the
push rod.
A. Push Rod Puller: 57001'289
C'Up and down the push rod for bleeding the air in the
inner tube. Continue the bleeding until the push rod
moves smoothly.
DUsing oil cylinge (special tool: 57001-1290), check the
oil level (see Oil level Adjustment).
o lnstall the spring and spring seat.
o PuIl up the push rod.
Olnsert spring holder (special tool : 57001-1286) under
the push rod nut (see Oil Level Adjustment).
o Remove the push rod puller.
o lnstall the top bolt and tighten it to the specified
torque.
Tightening Torque
27 N-m 12.8 kg-m, 20 ft-lb)
_ Remove the front fork.
- Hold the front fork with a vise.
- Unscrew the top bolt.
_I nsert the spring holder (special tool) under the push
rod nut.
A. Spring Holder: 570011286 C. Spring
B. Push Rod Nut D. Top Bolt
- Remove the top bolt.
- Remove the spring holder.
_ Remove the spring.
A. Spring
_ Remove the washer.
)
A. Washer
_ Remove the push rod nut, and remove the spring guide.
A. Push Rod Nut B. Spring Guide
_ Pour the fork oil into a container.
_Clean the bottom of the inner tube.
_ Remove the caps on the bottom of the inner tubes.
- Hold the front fork with a vise.
- Stop the cylinder from turning by using the front fork
cylinder holder (special tool). Unscrew the cylinder
valve assembly, and take the cylinder valve assembly
and gasket out of the bottom of the inner tube.
Cylinder Valve Assembl y Inst allation/ Removal
I
I
1. Cylinder Holder: 57001-1286
2. Cylinder Unit
3. Cylinder Valve Assembly
45
_ Remove the cylinder unit and push rod from the top of
the front fork tube _
_ Remove the stopper, collar, guide, circiip, and O-ring
off the push rod.
A. Stopper D. Guide
B. Collar E. O-ring
C. Circlip
A. Push Rod Assembly B. Cylinder Unit
_Separate the inner tube from the outer lube as follows.
oSlide up the dust seal.
o Re move the retaining ring from the outer tube.
B
A. Retaining Ring C. Dust Seal
B. Outer Tube
46
o Hording the inner tube by hand in a vertical position,
stroke the outer tube up and down several.times and
pull it down. This shock to the fork leg separates the
outer tube from the inner tube.
e Remove the guide bushes, washer, oil scal, retaining
ring, dust seal from the inner tube.
A. Guide Bushes
B. Washer
C, Oit Seal
D. Retaining Ring
E. Oust Seal
F.lnneTTube
fOther than US and Canadian Models)
e Assembly is the reverse of disassembly.
e Check the O-ring at the top bolt. Replace it with a
new one if damaged
Replace the oil seal (cmoved with a new one.
e Replace the guide bushes with new ones.
-I nstall the dust seal, all seal, washer, guide bushes on
the inner tube.
_ Drive the oil seal and guide bush into the outer tube
with the front fork oil seal driver (special tool) ,
051it of the gui de bush must be faced toward the wheel,
A. Front Fork Oi l Seal Driver: 570011288
B. Oil Seal
C. Slit
e lnstall the retaining ring.
A. Retaining Ring B. Dust Seal
el nstall the dust seal into the outer tube.
e lnsert the push rod in the cylinder unit.
A. Cylinder Unit B. Push Rod
_ Install the gu ide, rollar, stopper, circlip, O-ring on the
push rod.
A. Stopper D. Guide
B. Coll ar E. O-ring
C. Circlip
- Install the rollar on the guide, and tighten the stopper
to the specified torque.
Tightening Torque
26 N-m (2.7 kg-m, 19_5 ft-Ib)
-I nsert the push rod and cylinder unit into the outer
tube.
_Apply a liquid gasket to both sides of the gasket, and
apply a non-permanent locking agent to the threads of
the cyl inder valve assembly at the bottom of the inner
tube.
_Stop the cylinder from turning by using the front fork
cylinder holder (special tool: 57001-1287), tighten the
cylinder valve assembly to the specified torque.
Tightening Torque
54 N-m (5.5 kg-m, 40 t ~ b
_I nstall the cap on the bottom of the outer tube.
_ Pour in the type and amount offork oil specified, and
adjust the oil level as follows (see Fork Oil Change).
o Lift up the outer tube so that outer tube upper end
becomes higher 10 mm than inner tube upper end.
OPour in the fork oil up to the inner tube upper end. At
this time, pour the fork oil into the push rod hole, too.
A. OuterTube
B. Inner Tube
C. Push Rod
47
OUp and down the outer tube to fill the fork oil in the
inner tube.
0 00 not move the outer tube move than 300 mm. Or
oil seal may be damaged.
oContinue above procedure until specffied amount of
fork oil goes into the front fork .
_Screw in the push rod puller {special tool} onto the
push rod.
A. Push Rod B. Push Rod Puller: 57001-1289
_ Up and down the push rod for bleeding the air in the
inner tube_ Continue the bleeding until the push rod
moves smoothly.
_ Remove the push rod puller.
_I nstall the spring guide and push rod nut at the push
rod.
o lnstall the spring guide so that the hole comes lower
side.
48
A. Push Rod C. Hole
B. Spring Guide
e lnstall the push rod puller (special tool : 57001.1289).
e lnstall the washer into the outer tube.
e lnstall the spring.
_ Pull up the push rod.
e lnsert the spring holder (special tool) under the push
rod nut.
A. Push Rod C. Spring Holder: 570011286
B. Nut
e Remove the push rod puller.
-I nstall the top bolton the push rod .
Remove the spring holder,
el nstall the top bolt on the top of the fork tube and
tighten them to the specified torque.
Tightening Torque
29 N-m (3.0 kg-m, 22 ft.j bl
el nstall the front fork.
.................................. .. .. .................................... ..
Rear Suspension (Unit rak)
.. ......................................... ................................ ..
Rear Shock Absorber :
Shock Damping Adjustment
e The location of rebound damping adjuster is changed
as shown.
A. Rebound Damping Adju5ter B. Mark
Rear Shock Absorber Disassembly (Oil Change)
e After releasing nitrogen gas, remove the air bleeder
bolt, and pump the rear shock to drain the oil out of
the rear shock body and the gas reservoir. It makes
easy to push the reservoir cpa in.
Steering
Exploded View
Electrical System
............................................................................
Exploded View
KX125:
11 : 5.9 N-m (0.6 k,'m. 52 inlbl
T2: 27 N-m 12.B kgm, 20 ftlbl
49
T1 : 25 N-m 12.5 kg-m, 18.0 ft-tb)
KX250:
T2
50
........................................ ... .. ..... .......... ........... .....
Wiring Diagram
.. ......................... ................ ........................ .. .. .. ...
KX125/250
1. Spark Plug
2. Ignition Coil
3. COl Unit
4. Pickup Coil
5. Excitor Coil
6. Stator Coils
7. Magneto
8. Engine Stop Button
KX500:
} n
H
} n @
ISl
(j)
1. Spark Plug
2. Ignition Coil
3. COl Un it
5. Magneto
6. Pi ckup Coil
7. Excitor Coi l
8. Stator Coils
Specifications
Item
Ignition System:
Ignition t iming: KX125
KX250
COl unit internal resistance
Spark plug:
Ignition System
Spark Plug Gap
0.5 - 0.6 mm
COl Unit Inspection
Spark plug gap
51
Standard
13.8 BTDC@ll000r/min Irpm)
14 BTDC @6000 rl min Irpm)
refer to page 51
0.5 - 0.6 mm
NOTE
oAsterisk (.): When ropeating the test idlcated with en
asterisk, wait for more than 30 minutes befors next
trial to get a reliable result.
Stator Coil Resistance:
KX125, KX250:
Connection Reading (20 C 168 F)l
Black/White - Black/Yellow 376- 564 n
White/ Red - White/Green 176 .... 264 n
e For KX125-Gl and KX250-Gl models, make the
measurements shown in the table.
Range: x 100 n
COl Unit Test Usi ng the Kawasaki Hand Tester
KX125, KX250:
Tester Positive (+) Lead Connection
Black{White
White/Red White/Green Black Black/Yellow
Lead Color 15top)
(Pickup 1) (Pickup 2) (Ign. Coil) (Ground)
(Exciter 1)
Black/White
~
500'
c
15top) 150-350 190-400
,
150-300
0
(Exciter 1)
-
~
u
~
500'
c
White/ Red
c
2.8 - 4.2 10-12 I 0
8
(Pickup 1)
-

~
500'

White/Green
I
(Pickup 2)
17 -24 10-12
,
10-12
-
-

~
>
~
Black
!lo
(Ign. Coil)
9-20 3-44 10-24 2.9 - 4.5

z
"
500'
~
B
Black/ Yell ow

2.8-4.2 0 10-12 I
~
(Ground)
-
Black/ Red
17 - 35 8.5-12* 24 - 30 500' 8.5 -13
(Exciter 2)
,
I I I I
120-1000 50-100 80-100
-
50-100
00 : Infinity Range : x , kS1 Unit : kS1
Black/Red
(Exciter 2)
400 -1000
3.0- 4.4
17-24
9.5 - 20
2.8'" 4.4
~
MODEL APPLICATION
Year Model Beginning Frame Number
KX12S.Gl JKAKXRG1DKAOOOOOl or KX125G'{)()()()()1
1989 KX250.Gl JKAKXMG10KAOOOOOlor KX25QG.{)()()()()1
KX500-El JKAKXVE10KAOOOOOl or KX500E.()()OO()l
o : This digit in the frame number changes from one machine to another.
Kawasaki
KX500
Motorcycle
Service Manual
Supplement
This supplement is designed to be used in conjunction with the '88 KX125IKX250/KX500 Motoorcycle
Service Manual (PI N 99924-1101-01) . The maintenance and repair procedures described in this supplement
are only those that are unique to '90 and up KXSOO motorcycles. Most service operations for thi s model
remain identical to those described in the base Service Manual. Complete and proper servicing of the '90
and up KX500 motorcycles therefore requires this Supplement and the base Service Manual .
Table of Contents
General Information
Befor. Servicing ..... . ..............
Model Identification ... . ... . .........
Genera' Specifi cations ............. . .
Periodi c Maintenance Chart .... , " ..
Torque and Locking Agent , .. , .........
Cable Routing, .... . ...............
Fuel System
Exploded View , ... . .. . .... . .......
Speci fications ..... . . . . . ............ .
Specia' Tools ..... . .......... , .....
Throttle Grip and Cable ...............
Throttle Grip Free Plav InlP8ctlon . . .. ,
Throttle Cable Adjustment . . ....... .
Throttle Cabl_ Inst.llrtion Note . . ....
Throttle Cable Lubrication . . ...... . .
Throttle Cable Inspection . ......... .
Carburetor .. , ..... .. .. , . ....... , , ..
Idle Speed Inspection ............. .
Idle Speed Adjustment. , .. . . ,
Service Fuel Le .... 1 Inspection . . ...... .
Service Fuel Level AdJustment ...... . .
Fuel System Clean ....... . .... . ..
C.rburetor Remover ... ..........
CIIrburetor Instlilnion Notes . . . .. . . . .
Clrburetor Disassembly .... .. ..... .
CIIrburetor Assembly Notes .... ... . .
Carburetor Clelning ........ . . ...
CIIrburetor Inspection ............ .
Air Cleaner . . .......... . .. . ........ .
Air Cleaner Housing RemOllal . .. . . .. .
Air Cleaner Housing Installation Notes . .
Air Cle."er Element Removal .. . .... .
Ai r aeaner Element Instllletion Note ..
Air Cleaner Elemant CI .. ning
and Inspection ..... . .........
Fuel Tenk ....... . . . . . . . ... . ...... .
Fuel Tank Remonl . ........... . .
Fuel Tenk Installation Notes ....... . .
Fuel Tap RemOllel .... . . . .. .. ..

6
7
9
10

11
11

Fuel Tap Inst.lIation Notes ...... . ..
Fuel Tap Inspection .............. .
Fuel T."k Cap Inspection . . .. . ....
Fuel Tank and Tap Cleaning .. .. .. .
RNd Valve ... ....... ... . .... . ...
Reed Velve Removal .... .. ... . . . . .
Reed Velve Installetion .. . ..
Reed ValV!! Inspection ....... . ....
Cooling System
Exploded View . ... . ...... . . . .... . .
Specification . . ........ . ..... .. ..
Speciel Tool . . ............ . ... .. .
Coolant ... . . . . .. . . .. ....... . .
Coolant Inspection ..... ....
Coolant Change . . ....... . .. . . . ..
Air Bleeding .. ' ........... . ... .
Cooling System Pr.ssure Testing .. . ... .
Cooling System Flushing .........
Dlnuembly and Auembly Precautions . . . . . .
Water Pump ................ . .
Weter Pump Cover Removal ........
Wner Pump Cover Installation Notes . .
Impeller R.moval ..............
Impeller Inn.llnlon ... .. .. . ....
Impellerlnspection ........... . .
W.ler Pump Sheft Remov.l .........
Wner Pump Shaft Installation Notes .. ..
Oil Seal Removal ......... .. .
Oil Sa.l l nstallallon ....... . .... . . .
Radletor .... ... . .. . ...... . ..
Radiator Removal .. . ... . . .
Radinor InsUllation .. . . .. . .. .
Radiator Inspection .. .. .. . .......
Radl.tor C.p InlP8ctlon .........
Filler Neck: Inspection ... . . .. . .
Cooling Hoses,
Breather Hose Inspection . .... . .. .
Cooling Hoses,
Bre.ther HOM Installellon Notes . . . .
1

12

12

12

2
Engine Top End
E)(ploded View ..... . .. . ..
SpeciflCltions ............. , .. . ...
Speci. l Tools ................ . . . .
Cylinder Held ... . .. . .. , ........ , ... .
Cyl inder ComprH.lon Measurement .. . .
Cylinder Held Removal ... . ... , ...
Cylinder Held Installation Notes . , , ...
Cyl inder Held Warp Inspection .... . .
Exhaust Valve (KIPS) . , . . , .... .
Exhaust V.lve Ramoval .... . .
Exhaust V.lvt lost.Hnion Notes .. .. , .
Cylinder, Pi ston ..... . .. . ..... . . ... . .
Cylinder Removal . , . , , .. . ..
Cylinder Inst.llation Notes .... ...
Piston Removal ...... . .......
Pi lton Instlll.lion Note . , .... .. ..
Cylinder Wear Inspection .. , .. . .... .
Piston Ol.meter Mea.urement .. . ... .
Pi. ton/Cylinder Clear.net .. , .. . .. , .
Piston Ring,
Piston Ring Groove In&peetion .... . .
Piston Ring End Gap Inspection ... . .. .
Piston, Pi ston Pin,
Connecting Rod Weer Inspection ...
Mufflar (Expansion Chamber, Silencer) ....
ExPansion Chamber RemOlJal ..... . . .
Expansion Chamber I nsuUation Notes ..
Silencer Wool Change .. . . . . . . . .. .
Engine Right Side
Exploded View ... . .. . ....... .. .
Specifications ... .. . . ... .. . . ... .
Specill Tools .. . . . .......... . ....
Right Engine Cover . . . . ...........
Right Engine Cover Removil . . . . . ...
Right Engine Cover Inltallatlon Notes .. .
Right Engine Cover Dillssembly .. , . .. .
Exhault Advancer Assembly
DlsaS5embiy/Auembly Notes . . ... , .
Right Engine Cover Assembly Notes ..
Clutch . ... . . .. . ,", ....... . . " .. .
Clutch Adjustment , , . .. . ... , , ,
Clutch Removal/ Disassembly ... . , , , .
Clutch Insmllation Notes . , . , ... . , .
12
13

13

13

13
13
13
13

13
14

14
14

14

14
14

16

16

16

16
Friction Pllte Wear,
Damage Inspection . , ..........
Frlction and Steel Plate
Warp Inspection . , ..... , .
Clutch Spring Free Length
Measurement ...... .........
Clutch Pl ate/Clutch Housi ng
Clearance .............. ..
Clutch Hub Splinl Inspection ... . ... .
External Shift Mechanism .. . ........... .
External Shift Mechanism Removal .... .
Installation Notes , ............ .
Inspection ........ . . . .... . .
Primary Gear . . . , .... . . . . , .......
Primary Gelr Removal ....... . .... .
Primary Gear Instillation Notes . . .... .
Kick Starter ..... . .... , .... . ..... .
Kick Shah Assembly Removal , ...... .
Kick Shaft Assembly Instailition Notes ..
Kick Shaft Auembl y
Disassembly/Assembly NotH . .... .
Kick Starter Idle Gear Removal Notes. , .
Kick Stlrter Idle Gear
Instilletion Notes . , . , ......... .

Exploded View .. . ......... , , . . . .. .
Engine Removal / Installation ..... ...
Engine Removal . . ... , ..... ...
Engine Installation Notes ... , ... . .
15

Engine Bottom End
/Transmission
Exploded View ....... , . . . ........
Specifications .. , .... . ... . , ... . ..
Special Tool .. . . . ........
Transmission 011 ... , .............
Oil Level Inspection . . . ... , , . .. ,
Oil Change .... . . . . .. , , . . ...
Crankcase Splitting .. .. ..... .. .
Cr.nkcae Splitting . , ... . ......
CrankctS8 Assembly .. , .......... .

16

16
Crankshaft , Connecting Rod .. .. ........ .
Crankshaft Removal. ............. .
Crankshaft Installation Notes ....... , .
Crankshaft Disassembly Note ........ .
Crankshaft Assembly Notes .........
Radial Clearance .... . .........
Big End Seizure ................
Side Clearance ....... . ......
Crankshaft Runout ........ . ..... .
Crankshaft Alignment ............ .
Transmission ...................... .
Transmission Shaft Removal ........ .
Transmission Shaft Installation Notes .. .
Transmission Shaft DiUlssembly Notes .. .
Transmission Shaft Assembly Notes ... .
Shift Orum and Fork Installation Notes ..
Shift Fork Bending .....
Shift Fork/Gear Groove Wear
Shift Fork Guide Pin/Shift
Drum Groove Wear ..... . .. . .. .
Gear Damage .................. .
Gear Dog/Gear Dog Hole Damage ..... .
Ball Bearing Wear ............... .
Wheels/ Tires
Exploded View . ... . . . .. ...
Specifications ........... , .... . ..
Special Tools . .....................
Wheels ................. . ......... .
Front Wheel Removal ............. .
Front Wheel Installation Notes ....... .
Rear Wheel Removal ............. .
Rear Wheel Installation Notes ....... .
Wheel Alignment Inspection ........ .
Wheel Alignment Adjustment ..... ..
Wheel Inspection ...............
Spoke Inspection ................
Rim Inspection ..... , ...... . ,
Axle Inspection. , ...... ....
Tires , .. ... . .. .. , ........ , ... ,.
Tire Removal ................. , .
Tire Installation Notes ...... , .. , . . .
Tire Pressure Inspection/Adjustment. , ..
Tire Inspection .. , . .. ' .... , .. ... .
Hub Bearing ..... . , ....... , .. , ..... ,
Hub Bearing Removal Notes ... , .... .
Hub Bearing Installation Notes, . , .... .
Hub Bearing Inspection
and Lubrication .. , ........... .
Grease Seal Inspection
and Lubrication .... , . , ' ...
16

16

16

16

17
17

,8
18
18
19
19

Final Drive
Exploded View , .. .
Specifications ...... , ... . . . . ...
Special Tools, ..... , .... , . . , .. , .... ,
Drive Chain ..... , ....... . . , .... , . , ,
Drive Chain Slack Inspection .. , , . .. , .
Drive Chain Slack Adjustment .. , .... .
Wheel Alignment Inspect ion ........ .
Wheel Al ignment Adjustment ... , .. .
Drive Chain Wear Inspection ........ .
Drive Chain Lubrication ......... ..
Drive Chain Removal ..... . .... ...
Drive Chain Installation Not es .... .. .
Sprocket .............. .
Engine Sprocket Removal ........ .. .
Engine Sprocket Installation Notes.
Rear Sprocket Removal .... , .. , . , ..
Rear Sprocket Installation Notes . , ....
Sprocket Wear Inspection. , .... , . , ..
Sprocket Warp Inspection .......... .
Brakes
19

20

20
20

Exploded View . , , .. , , .. , , , . . .... ,. 21
Specifications ... , .................
Special Tool ............ . ....
Disc Brakes .... , ......... , . .. . .. .
Brake Adjustment ..... , .. , ........ .
Brake Lever/ Pedal
Free Play/Adjustment ..... .. .. . .
Front Brake Lever Pl ay Adjustment ... .
Rear Brake Pedal Position
Adjustment ....... .. .......
Rear Brake Pedal Play Adjustment ....
Caliper .... . .. .... . ......... ..
Caliper Removal ................
Caliper Installation Notes .......... ,
Caliper Disassembly ........ ' ...... .
Caliper Auembly Notes ...... ..... .
Fluid Seal Damage , . , . , , ......... .
Dust Seal and Cover Damage . ....... .
Piston Cylinder Damage ........... .
Caliper Holder Shaft Wear , ......... .
Brake Pads , .... " ..... ,., ......
Pad Removal .. . ..... , , ... , ... .
Pad Installation ......... , ...... .
Pad Inspection ................. .
Master Cylinder .. ' .... , ...... ' ...... .
Front Master Cylinder Removal .... . .
Front Master Cylinder
Installation Notes, .... , .......
21

22

22
22
22
22
22

23
23
23
23

3
4
Rear Master Cylinder Removal .. . . . .. .
Rear Master Cylinder Installation Notes ..
Front MISter Cyli nder Disassembly .... ,
Rear M.ster Cylinder Dlsassemblv . .. . .
Master Cvllnder Assembly Notes ..... .
Master Cylinder Inspection
(Visual I nspecticn) . ..... , ...
Brake Disc ....... , .. ... . . . . .
Disc Inspection ........ . ......
Brake FluId . . . . ......... . .......
Brake Fluid Requirement .... . .. ...
Brake Fluid Level Inspection . . .. . , .. .
Bleeding the Brake line ........... .
Brake Hose . ........ , ............ .
Brake Hose Removal / Installation Notes . ,
Brake Hose inspection ............ ,
Suspension
Exploded View ........... . ... , ...
Specifications .. . . . . . .. ..........
Speci al Tools ................. ...
Front Fork. , ......... , ........... .
Front Fork Adjustment .......... . .
Front Fork Remol/al (Each Fork Tube) ..
Front Fork Installation Notes ..... . . .
Front Fork Disassembly ........ . .. .
Front Fork Assembly ............. .
Inner Tube Inspaction ........... . .
Guida Bush Inspactioi'! ............
Oil Seal and Dust Seal Inspact lon .... . .
Spring Tension ................. .
Rear Suspension tUnlTrakl ...... . ...... .
Rear Shock Absorber ...... . . ... ....
Shock Damping Adjustment ..... .. . .
Rear Shock Absorber Ramol/al. ... . .. .
Reaf Shock Absorber Installation Notes ..
Rear Shock Absorber Spring
Replacement ................ .
Reaf Shock Absorber Dimsembly
(Oil Change) ................. .
Swing Arm .. . ................... .
Swing Arm Removal .............
Swing Arm Installation Notes .. .. ..
Tle Rod. Rocker Arm .... .. ...... . .
TleRod Remol/al . . .. ........ ..
Tle Rod Installation Notas .........
Rockar Arm Remol/al. . .. . ........ .
Rocker Arm Instillation Notes ....... .
UnlTrak Maintenance .............. . .
Sleelltl ... . ..... ..............
Rocker Arm .............. . ..
Mounting Bolt Bend ........ ..

24
25
26
27
27
31
31
31
34
37
:rJ
37
37
38
38
38

38

Steering
Exploded View ...... . . . . ....... ..
Special Tools . .... . . . ........... . .
Steering Adjustment .......... ..
Steering Inspect ion ........... ..
Steering Adjustment .......... . ..
Steering Remol/al / lnstallation ...........
Steering Stem Removal ............ .
Steering Stem Install ation Notes ...... .
Steering Stem Race Removal ........ .
Steering Stem Race Installation Notes .. .
Steering Maintenance .. . .............. .
Steering Stem Bearing Lubrication .... .
Bearing Wear. Damage . . .......... .
Steering Stem Warp ............. .
Electrical System
Exploded View . . .......... . ......
Wiring Diagram . .. ....... ........ . ..
Specificatioos ........... ....... .
Special Tools ........ . .. ... .
Precautioos ............. . ... . ...
Electrical Wiring ......... ..... . . ..
Wiring Inspection .......... .. ..
Ignition Timing ......... . . . ...... ..
Ignition Timing Adjustment . .. . ...
Flywheel Magneto ........... . .... . .
Fl ywheel Magneto Ramol/al. ...... . . .
Flywheel Magneto Installation ....... .
Flywheel Magneto Inspection .......
Ignition System ................ . .. . :
Safety Instructions ..............
Ignit ion Coil Removal ...... . . . ... .
Ignition Coil Installatloo . . .. . ...... .
Ignit ion Coil Inspectioo ........ . .. .
Spark Plug Cleaning and Inspect ion .... .
Spark Plug Gap Inspect ion . ..... . .. .
COl Unit Inspectioo . ... . .........
Stator Coil Inspection .. . ... . .. . . . .
Appendix
Troubleshooting Guide
General Lubrication
Unit Conl/ersion Table ... . . . .... . . . .
Supplemenl2OOQ ....... 2004 Models .. .
... Refer to Base Manual

39
39
40

40

40

40
40
40

1-1
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
' c
DC
F
' F
It
9
h
L
ampere(s) Ib pound(s)
after bottom dead center m meter(s)
alternating current min minute!s)
after top dead center N newton!s)
before bottom dead center Pa pascal Is)
bottom dead center
before top dead center
degree!s) Celcius
direct current
fa,ad(,)
degree!s) Fahrenheit
foot, feet
gram!s)
houri,)
lited,)
WARNING
CONTAINS
ASa'STOI
PS horsepower
psi pound!s) per square inch
,
revolution
rpm revolution(s) per minute
TOC top dead center
TIR total indicator reading
V voltls)
W watt(s)
n
ohm(,)
This waming may apply 10 any of the following
components 0( any assembly containing one or
more of these components;
Brake Shoes or Peds
Gaskets
Insulators
SAFETY INSTRUCTIONS
. Operate if possible out of doors or in 8 well
ventilated place .
Preferably use hand tools Of low speed tools
equipped, if necessary. with an appropriate dust
extraction facility. If high speed tools are used,
they should always be so equipped.
el f possible, dampen before cutting or drilling,
e Dampen dust and place it in property closed re-
ceptacle and dispose of it safely.
Read OWNER'S MANUAL before operating.
5
6
General Information
............................................................................
.................................................. ............ ..............
KX600-E2
KX51JO.E3
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight: Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark plug: E2, E3
E4 -
Port timing:
Inlet: Open
Close
Scavenging: Open
Close
Exhaust: Open
Close
Lubrication system
Drive Train:
Clutch type
Type
Reduction ratio
KX500-E2 -
2190 mm
815mm
1 205 mm
1490 mm
370mm
950mm
100 kg
52 kg
54 kg
9.9 L
Liquid-cooled
86.0 x 86.0 mm
499 mL
7.4 ; 1 (High speed), 8.3: 1 (Low speed)
47.4 kW (64.5 PS)@7 000 r/ min (rpm)
66.7 N-m (6.8 kg- m, 49.2 h- Ib) @6 000 r/ min (rpm)
Primary kick
COl
19" BTDC @6 000 r/ min (rpm)
NGK B8EG. (C. U) NGK 8R8EG
NGK B8EG. (A. C. E. U) NGK BR8EG
Full open
60" BBDC
60" ABDC
83.5' BBDC (Low speed), 93.5' BBDC (High speed)
83.5" ABDC (low speed). 93.5" ABDC (H;gh speed)
Petrol mix (32 : 1 )
Gear
2.538 (66/ 26)
Wet. multi disc
7
8
Items
Transmission:
Type
Gear ratios:
Final drive system:
Type
1st
2nd
3,d
4th
5th
Reduction ratio
Overall drive ratio
Transmission oil:
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire:
Rear tire:
Make/Type
Size
Make/ Tvpe
Size
Wheel travel
Wheel travel
Grade
Viscosity
Capacity
KX500- E2 -
2.000 (32/ 16)
1.444 (26/18)
1.18t (26/ 22)
0.954 (21 / 22)
0.791 (19124)
Chain drive
3.357 (47/ 14)
6.746 @Top gear
SE class
SAE 10W30 or 10W40
0.8 L
Tubular. single down tube
45' to either side
27"
116 mm
DUNLOP K490 (E, U) DUNLOP 0752, Tube type
80/ 100- 21 51 M
DUNLOP K695 (E, U) DUNLOP 0752, Tube type
120/ 90-1966M
310mm
Swing arm (Uni -Trak)
330mm
Single disc
220mm
Rear 190 mm
Specifications are subject to change without notice. and may not apply to every country.
(A) : Australian model
(C) : Canadian model
(E) : European model
(U) : U.K. model
9
.... ... .......... ... ........... , .. .......... ...................... , ......... .
Periodic Maintenance Chart
............ , .... .......... ... ....... " ... .................. ........... ..... .
FREQUENCY
Each Every Every Every As
OPERATION
Clutch-adjust

Clutch and friction plates-check t

R
Throttle cable-adjust


R

Air cleaner element-replace
Damaged
Carburetor-i nspect/adjust

w
Transmission oil--chance

z
Piston and piston ring--clean/check t

R
'"
Cylinder head, cylinder and exhaust
z
valves-inspect

w
Muffler--clean/ check t

Silencer wool --change

Small end bearina.-check t

R
KickDedal and shiftoedal --clean

Exhaust pipe O-ring-replace


Coolant--check t

R
......
Radiator hoses, connections--check t


Brake wear--check t

Brake fluid level --check t

Brake fluid--chanoe Every 2 years
Every 2 years
seal--replace
Brake caliper piston seal and dust seal--replace Every 2 years
Brake hose and pipereplace Every 4 years
Spoke tightness and rim runout--check t

Drive chain--ad ust

Drive chain- lubricate

Drive chain wear--checkt

'"
Chain slipper and Quide- replace
Damaged -
lJl
Front fork-inspect/clean

I I I I

:I: Front fork oil--change
1 st time after 2 races, then every 5 races
U
Nuts, bolts, fasteners--check t
I I I I

Fuel hose-replace
Everv 4 ears
Fuel s-ystem--clean

Steering play--check t

Steering stem bearing-grease

Rear sprocket--check t

General lubrication- perform

Wheel bearinc-orease

Swing arm and Uni -trak linkage pivots-check t

Swing arm and Uni-trak linkage pivots-grease

Rear shock oil-replace
1 st time after 2 races, then every 5 races
t Replace, add, adjust or torque if necessary. R : Replace
10
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. I f insufficiently
tightened, a bolt or nut may become damaged or falloff, possibly resulting in damage to the motor-
cycle and injury to the rider. A bolt or nut which is overtightening may become damaged, strip an
internal thread, or break and then fall out. The following table lists the tightening torque for the
major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a
turn and then tighten to the specified torque.
Letter used in the " Remarks" column mean:
L : Apply a non-permanent locking agent to the threads.
LG : Apply liquid gasket to the threads.
5 .: Tighten the fasteners following the specified sequence.
Fastener
Nm
Fuel Sy.tem:
Rear Frame Mounting Bolts (Upper) 34
(Lower) 26
Cooling System:
Water Pump Impeller Bolt 6.9
Engine Top End:
Main Exhaust Valve Cover Bolts 9.8
Engine Removal/Installation:
Engine Mounting Nut (10 mm ~ i s . 34
Engine Mounting Bracket Nut
(8 mm ~ i s . 26
Engine Mounting Bracket Bolt
(8 mm Oia.) 26
Whael/Tires:
Front Axle Nut
54
Brakes:
Brake Pad Bolts 18
Caliper Bleed Valve 5.4
Suspension:
Front Fork Top Bolts 29
Front Fork Clamp Bolts (Upper) 21
(Lower) 20
Front Axle Clamp Nuts 8.8
Push Rod Nut 20
Guide Stay Nut 27
Front Fork Protector Bolts 8.8
Front Fork Cylinder Valve Assembly 54
Rear Shock Absorber Mounting Bolts 34
Tie-Rod Mounting Nuts 81
Rocker Arm Nut 81
Steering:
Handlebar Clamp Bolts 25
Torqua
Remarks
kltm ftlb
3.5 25
2.7 19.5
0.70 61 in-Ib
1.0 87 in lb
3.5 25
2.7 19.5
2.7 19.5
5.5 40
1.8 13.0
0.55 48 in-Ib
3.0 22
2.1 15.0
2.0 14.5
0.90 78 inlb
2.0 14.5
2.8 20
0.90 78 in-Ib
5.5 40 L
3.5 25
8.3 60
8.3 60
2.5 18
Fuel System
............................................................................
Exploded View
........................................................ ...... ..............
............................................................................
Specifications
.................................................................... ..... .
Item
Make/t ype
Main jet
Jet needle
Slow jet
Air screw
Service fuel level
Bore center
Float height
T1: 34 N' m (3.6 ki"m, 25 ftlb)
T2: 26 N'm (2.7 ki"m, 19.5 ft.lb)
Standard
KEIHIN PWK 39
168
7
N82M
3rd groove from the top
60
1 % (tu rns out)
- 1.0 1 mm
34mm
16 1 mm
11
12
Reed Valve
........ ......... .............. ..................... .......... .. ............
Reed Valve Installat;on
_Install the reed valve holder as shown.
Upward
D
D
Downward
o 0
o
oD-o
Engine Top End
o
................. .. .. ................................... .. ................ ..
Exploded View
Cooling System
. ................................ .............. .. ........ .................. .
Exploded Vi ew
T1 : 6.9 N' m (0.70 kg-m. 61 In-lb)
T1 : 9.8 N' m 11.0 kst'm. 87 in-lb)
Specifications
Item
Cylinder, Piston:
Piston diameter
Piston/cylinder clearance
Piston pin hole diameter
Cylinder Head
Cylinder Head Insta/lation Notes
-Install the cylinder head gasket as shown.
o
~ o

4
1
1. Metal Section
2. Short
3. Long
4. Short side faces upward.
1
..................... ....................... ................................
Exhaust Val (KIPS)
................ ......... ... ....... .. .......................................
.For KX500-E2 and up models, removal is the same as
fOf the KX250-G1 .
Exhaust Valve Instal/ation Notes
-Be careful not to mix up the right and left exhaust
valves. The right valve has an ident ifi ng groove.
13
85.905 - 85.920 mm 85.76 mm
0. 100 - 0. 130 mm ---
19.000 - 19.020 mm 19.07 mm
1. Groove:
For KX500- E2 and up models, installation is the same
as for the KX250-G1 , except for the specified torque of
the leh plug on the cvlinder.
Specified Torque
20 N' m (2.0 kg-m. 14.5 ft.lb)
. ................ .................... ...................................... .
Cylinder, Piston
...................... ......................................................
-Measure the outside diameter of the piston 26.5 mm
up from the bottom of the piston at a right angle to
the direction of the piston pin.
*I f t he measurement is under the service limit, replace
the piston.
Pi.ton Diameter
Standard: 85.905 - 85.920 mm
Service Umtt: 85.76 mm
14
A : 26.S mm
Piston/ Cylinder Clearance
Pilton/Cylinder Claaranet
Stllnderd: 0,100 - 0.130 mm
Engine Right Side
Exploded Viow
Specifications
.............................................................. ............. ..
Item
Clutch:
Steel plate th ickness
Friction plate tang width
Piston, Piston Pin,
Connecting Rod Wear Inspection
Pilton Pin Hoi. Diameter
Standard: 19.000 - 19.020 mm
Sen'ice Limit: 19.07 mm
Muffler I Expansion Chamber, Silencer)
Expansion Chamber Instal/ation
e Apply mol ybdenum disulfide grease to the O-ring on
the exhaust port.
1.41 - 1.59 mm 1.31 mm
13.6 - 13.B mm 13. 1 mm
.............................................................................
Right Engine Cover
Exhaust Advancer Assembly Disassembly/
Assembly Notes
eThe exhaust advancer assembly consists of the fol-
lowing parts.
1. Pins
2. Rod
3. Guide
4. ().ring
S. Steel Ball s
6. Holder
7. Needle Bearing
8. Spacer
9. Collar
10. Spring
11 . Gear
Exploded View
16
................................. ....................... .....................
Clutch
................. .. .. ........................................................
Clutch Installation Notes
. For KX500E2 and up models the toothed washer
between the clutch hub nut and the clutch wheel is not
on the whicle. Omit the maintenance work for the
toothed washer.
T1 : 34 N-m 13.5 kg..m, 26 ftlb)
T2: 26 N' m 12.7 kg-m, 19.5 ftlb)
16
Engine Bottom
End/ Transmission
............. ........ .. ....................... .. ....................... ......
Crankcase Splitting
Crankcase Assembly
_I nstall the bearing for the drive shaft Into the left
crankcase half 50 that stepped side faces inside .
Apply a nonpermanent locking agent to the threads of
the drive shaft bearing holder screws.
1. Stepped Side
2. Holders
3. Apply a non permanent locking agent.
Crankshaft. Connecting Rod
Cnlnkshaft Runout
_ Set the crankshaft in a ftywheel alignment jig or on V
blocks, and place a dial gauge against the points indio
cated.
_Turn the crankshaft slowly. The maximum difference
In gauge readings is the crankshaft runOUL
Cr.nkshaft Runout
Sund.rd:
Service Limit:
Not more th.n 0.03 mm
O.10mm
Turn the crankshaft
slowly.
1,9mm
Transmission
Drive Sh.ft G.lrs
1, 1st Gear (16T; part of drive shaft)
2. 5th Gear (24T; dog recesses face left)
3. 3rd Gear (22T; fork groove goes to the left side of the
gear teeth)
4, 4th Gear (22T; dog recesses face right)
5. 2nd Gear (18T; either side may face in)
5 4
Output Shift Gelrs
1. 2nd Gear (26T; dog racesses face right)
2. 4th Gear (21T; fork groove goes to the right side of
t he gear teeth)
3. 3rd Gear (26T; dog recesses face left)
4. 5th Gear (19T; fork groove goes to the left side of the
gear teeth)
5. 1 st Gear (32T; dog racesses face left)
Wheels/ Tires
Exploded View
Specifications
ltom
Tires:
Front: Size
Make, type
Rear: Size
Make, type
IE) : European model
IU): U.K. model
Stondard
80/ 100-2151M
T1 : 64 N-m (5,5 kg-m, 40 ft-Ib)
T2: 29 N'm 13.0 kg-m, 22 ftlb)
T3 : 98 N'm (10 kg-m, 72 ft-Ib'
Service Limit
---
DUN LOP K490 IE, U) DUNLOP 0752, Tube type
---
120/ 90-1966M
---
DUN LOP K695 IE, U) DUNLOP 0752, Tube type
---
17
18
Wheels
............................................................................
Front Wheel Removal
eReplace a stand or block under the motorcycle SO that
the front wheel is raised off the ground.
- Loosen the right axle clamp nuts.
-Unscrew the axle .
Pull off the axle, and remove the wheel.
A. Axle Clamp Nuts B. Axle
CAUTION
Do not 'IY the wheelan the ground with the disc
facing down. Thi. can dlmage or wlrp the disc..
PlKII block. under the ttl_I 10 the disc doe. not
touch the ground.
Remove the collars and caps on both sides of the
wheel.
elnsert 1iI wood wedge between the disc brake pads. This
position, should the brake lever be squeezed acciden-
tally.
Front Wheel Installarion Notes
-Fit the projection on the cap to the groove on the
collar.
A. Projection B. Groove
_If the axle nut has been removed, install it with the left
axle damp so that the left end of the hexagonal
portion touches the right end of the axle bracket .
A. Axle Nut Hexagonal Portion
B. Axle Bracket
C. Touch
. Tighten the axle to the specified torque.
Specified Torque
54 N m 15.5 k9'm. 40 ftlb)
.The arrow mark on the axle clamp must point upward .
A. Arrow Mark
.Tighten the upper damp nuts first, and tighten the
lower damp nu ts to the specified torque.
SpecIfied Torqu.
8.8 N'm 10.9 kg-m, 78 in-Ib)
_Check the front brake for weak braking power and
brake drag.
AWARNING
Do not attempt to drive the motorcycle until a full
brake lever I, obtained by pumping the brake levar
until the PMis ere againtt the disc.. The brake will not
function on tha fint application of tha levar jf thl' i,
not done.
Final Drive
Exploded View
19
Rear Wheel Removal
_Pull out the cotter pin, and remove the axle nut.
Rear Wheel Installation Notes
_I nsert a new cotter pin through the axle nut and axle,
and spread its ends.

T1 : 29 N-m (3.0 kv-m. 22 ft-Ib)
T2: 98 N-m 110 kv-m. 72 ft-Ibl
20
Drive Chain
Drive Chain Slack Adjustment
- Pull out the cotter pin, and loosen the axle nut.
A. Cotter Pin D. Locknut
B. Axle Nut E. Marks
C. Adjusting Bolt F. Notch
_After adjustment, insert a new cotter pin through the
axl e nut and axle, and spread its ends.
WhHI Al ignment Inspection
A. Marks B. Notches
Brakes
Exploded View
T2
Specifications
Disc Brake:
Item
Brake Pads:
Pad lining thickness:
Brake Disc:
Disc thickness:
T1

..
of
Front
Rear
Front
Rear
Standard
4.5mm
4.7 mm
T1 : 5.9 N'm (0.8 kg-m. 52 in-Ib)
T2 : 26 Nom (2.5 k9"m. 18.0 ftlb)
T3: B,8 Nm 10.9 kg-m. 78 i n-Ib)
T4 : 6.4 Nm (0.65 kll"m, 48 in-Ib)
T5 : 18 Nom (1 ,8 kltm, 13.0 ft-lb)
T6 : 9.8 N-m 11.0 kg-m, 87 !""Ibl
Service Limit
1 mm
lmm
2.85 - 3.15 mm 2.5mm
4.35 - 4.65 mm 3.8 mm
21
22
Disc Brakes
Caliper"
Caliper Removal
eRemove the disc cover.
A. Di sc Cover B. Mounting Bolts
-Loosen the brake pad bolts before the caliper removal
if the caliper is to be disassembled.
A. Caliper Mounting Bolts
B. Br.tke Pad Bolts
Caliper Instal/ation Notes
eTighten the brilke pad bolts to the specified torque if it
was removed.
Specified Torque
18 N'm U.8 kg-m, 13.0 ftlbl
Caliper Disassembly
Loosen the brake pad bolts before caliper removal, and
remove the brake pad bolts before the pad removal.
A. Brake Pad Bolts
e For the front caliper, there ife two pistons in the
caliper. Holdi ng the one piston in place, lightl y appl y
compressed air to where the brake line fits into the
caliper. Another piston comes out by air pressure.
Temporarily Insta ll the removed piston. Take care that
not to push it so far. Remove the remaining piston by
lightly applying compressed air to where the brake li ne
fits into the caliper.

To avoid ",ioul Injury, never place your fingeR or
palm Inlide the caliper opening. If you apply com-
preued air Into ttle caliper, the pilton may crUlh your
henct or fingeR.
NOTE
OW/Htn nmoving the pistons with braktt fluid preSlUr8.
temporarily inmll the pitton which Is removed fim to
remot/6 the remaining pinon es described sbove.
. Tighten the brake pad bolts to the specified torque.
Specified Torque
18 N'm (1.8 k\tm. 13.0 ftlbl
Brake Pads:
Pad Removal
Loosen the brake pad bolts before the caliper removal.
A. Brake Pad Bolts
Pad Installation
eTighten the brake pad bolts to the specified torque.
Specified Torque
18 Nm (1.8 kg-m. 13.0 ft lbl
Pad Inspection
_ Check the lining thickness and condition of the pads
in each caliper.
*If ei ther pad is damaged, replace both pads in t he
caliper as a set.
*If the lining thickness of either pad is less t han the
",t.
1. Service Limi t
Pad lining Thickness (mm)
Front Roar
Standard 4.5 4.7
Service Li mit 1 1
23
24
Suspension
... .. ........................................................................
Exploded View
L : Apply. noo-permanent locking
agent to the threads.
T1 : 21 Nom (2. 1 kg.m, 16.0 ft lb)
T2: 20 N' m (2.0 kg.m, 14.5 ftlb)
T3 : 29 N' m 13.0 kltm, 22 ftlb)
1'4: 27 N'm 12.8 kg.m. 20 ft-lb)
T6 : B.8 N' m 10.90 kg.m. 78 Infb)
T8: 54 N'm 15.6 kg.m, 40 ftlb)
TI : 81 N'm 18.3 kg.m. 60 ftlb)
T8 : 34 Nom (3.5 kltm, 25 ftlb)
25
Specifications
Front Fork:
Air pressure Atmospheric pressure
- - -
Rebound damping adjustment (Adjustable range)
(turn the adjuster counterclockwise) :
KX500- E2 10 clicks, (0) 8 clicks 16 clicks
E3 - E5
9 clicks, (0) 10 clicks 16 clicks
E6. E7 12 clicks 16 clicks
E8- El l 10 clicks 18 clicks
Compression damping adjustment (Adjustable range)
(turn the adjuster counterclockwise):
KX500- E2 8 clicks, (D) 12 clicks 16 clicks
E3 - E5
E6. E7 10 cl icks 16 clicks
E8 8 clicks 18 clicks
E9 - Ell
10 clicks 18 clicks
Oil viscosity SAE5W (KAYABA 01) - - -
Oil amount (per side) :
When change oil:
KX500- E2 approx. 375 mL - --
E3 - E5
approx. 445 mL, (0) approx 435 m - - -
E6, E7 approx. 430 ml
- --
E8
approx. 435 mL
- - -
E9 - Ell
approx. 520 mL
- --
After disassembly and completely dry:
KX500-E2 439 4 mL, (0) 443 4 mL
- - -
E3 - E5
521 4 mL, (0) 513 4 mL
- - -
E6. E7 508 4 ml
- --
EB 5144ml
- - -
E9 - Ell 6144ml - --
Oil level (full y compressed, without spri ng) :
KX500- E2 130 2 mm, (0) 125 2 mm - --
E3 - E5
110 2 mm, (0) 120 2 mm
- --
E6, E7 120 2mm
- - -
E8 1152mm
- - -
E9 - El1
110 2mm
- - -
Fork spring free length:
KX500 E2 533mm
522mm
E3 - E5
514 mm 504mm
E6 - E8
490mm 480mm
E9-Ell 470mm 461 mm
Rear Shock Absorbers:
Gas pressure 1 000 kPa (10 kg/ cm
2
, 142 psi)
- - -
Spring preload
(adjusting nut position from the center (adjustable range)
of the upper mounting hole) :
KX500-E2 - E5 122.5 mm, (0) 123.5 mm 109 - 130 mm,
(0) 109 - 132 mm
E6. E7 122.5 mm 109 - 130 mm
E8 - Ell 117.5mm 104-127mm
Rebound damping adjustment (adjustable range)
KX500-E2 9 clicks 16 cl icks
E3 - E5
14 cl icks, (0) 9 clicks 16 cl icks
E6. E7 14 cl icks 16 clicks
E9 - Ell
11 clicks 20 clicks
Compression damping adjustment (adjustable range)
KX500-E2 13 clicks 16 clicks
E3 - E5
E6. E7 14 clicks 16 cl icks
E9 - Ell 10 clicks 18 clicks
(0) : Other than US, Canada.
Front Fori< ( KXSOO- E2 - E7 )
"
,
16 o----@
Soher H,rd,r
(COUIHerClockwi5e ) (Ctockwin)
Number of turns countercl ockwise
usable range-16 clicks
A. Seated position wit h adjuster turned fuJly c lockwise.
Front Fori< ( KXSOO- E8 - Ell)
"
"
..
"
" $Qt. ...
(Co"""n;loc; . "", J
Numbw of ,,,rns coun,.n; __ s.
..... bI4o '."0--18 cllch CIt mOl.
A. Seat ed posi t ion with adjuster turned fully c lockwise.
Roar Shock Absorber ( KXSOO- E2 - E7 )
"
,
16 o---
Softer Hardtr
(Countercl ockwise) (Clockwife)
Number of turns counterclockwise
usable range-16 dicks
A. Seated position with adjuster turned fulty clockwi ...
Roar Shock Absorber ( KXSOO-E8 - Ell )
Rebound Damping Adjust ment
Numbolr 01 , um. countwclocl<wlM
u .. DIe ranQIt-20 dicb or trIOtiI
A. Seated position with adjuster turned full V c lockwise.
"
,
16 0 ----
Solter Harder
(Counterclockwise) (Clockwise )
Number of t urns counterclockwise
usable range16 clicks
A. Seated position with adjuster tumed fully clockWise.
..
"
"
$ol,e,

N"mber of ,,,,,,,
"s-tIIe f."p*19 c!,c .. o. "'0"
A. Seated position Wit h adjust er turned full y clockWise.
Compression Demping Adjustment
,...;.
.,
"
"
,
16 0 -----@
Soher H,rder
(Counterclockwise ) tClockwise)
Number of turns counterclockwise
ulable range-16 clicks
A. Seated po.ition with adjuster tumed fully clockwi ...
"
"
"
"
Number of '''rns coun1etdockwise
"uble .. ngoo 18 o;:IicQ at ""'"'
A. Seated positi on with adjuster tumed fully clockwise.
26
Special Tools
Fork SpJirti Holder: 67001-1286 Fork Push Rod Puller: 57001 1289
Oil Syringe: 57001 1290
Fork Oil Seal Driver: 57001-1340
Fork Cylinder Holder: 67001 1287
Jack: 57001-1238
/
............................................................ ... .............
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 adjustment you can make to
the front fork.
oAlr pressure adjustment - Air pressure acts as a
progressive spring and affects the entire r.imge 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
spnnglng. Your KX forks are designed to work
without adding any air.
OAebound damping adjustment - This adjustment
affects how quickly the fork rebounds. The fork
rebound damping adjuster has 16 or 18 clicks. The
~ t e position (full cfockwise until the adjuster stops)
IS fuff hard, and 16 or 18 clicks (fuff counterclockwise
until the adjuster SlOps) is full soft
o Compression damping adjustment - This adjustment
affects how quickly the fork compresses. The fork
compression damping adjuster has 16 or 18 clicks. The
seated position (full counterclockwise until the adjuster
stops) is fuff soh. and 16 or 18 clicks (fuff clockwise
until the adjuster stops) is full hard.
oOil level adjustment - The effects of higher or lower
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 oi l level (less oil)
will make the fork rebound more slowly.
o Fork springs - Optional springs are available that are
softer and stiffer than standard.
o Fork clamp position - Steering qualities are greatl y
affected by the fork clamp position (If the amount of
the inner tube projecting above the fork clamp). When
the fork tube height is smaller, the front end become
lighter due to the change in weiW"lt bias. Also, it tends
to understeer in tums and "wash out". When the
height is greater, the results are opposite.
Air Pressure Adjultment
_ Park the vehicle on level ground.
- To release the air pressure remove the screw at the top
of the front fork top plug.
Z7
A. Screw
Rlbound Dl mplng Adjustml nt
e Ta adjust rebound damping, turn the adjusters on the
front fork top plugs with the blade of a screwdriver
until you feel a click. Adjust the rebound damping to
the specified setting.
See the Specifications.
CAUTION
The left and r l ~ t fork tubel must hne the .. me
shock dl mpin;.
28
Compreu ion Damping Adjul tment
_Clean the bottom of the OlJter tubes.
Remove the caps on the bottom of the outer tubes.
eTo adjust compression damping. turn the adjuster on
the front fork cylinder valve with the blade of a screw-
driver until you feel a click. Adjust the compression
damping to the specified setting.
A. Adjuster
Compresston Da mping Adjustment
See the SpecifICations.
CAUTION
The left Ind right fork tubes mtltt h..,. the same
Ihock cbmping.
Oil Llval Adjustment
OIBining Oil
e Remove the front fork tube (see Front Fork Removal
in this chapter) ,
eHold the fork tube vertically, and unsc:rew the top
plug.
e Push the outer tube all the way down i.way from the
top plug and hold it there throughout the following
procedure.
_ Pull the 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.
A. Fork Spring
B. Push Rod Nut
- Use wrenches on the
loosen the rod nut.
A, Top Pl ug
B. SpringSeat
C. Fork Spring Holder:
57001-1286
rod nut and the top plug to
C. Fork Spring
_ Remove the top plug from the push rod.
_Lift the fork spring and its top spring seat out of the
inner tube.
_ Take the rebound damping adjuster rod (short) out of
the push rod.
A. Rebound Damping Adjuster Rod (short)
B. Push Rod
BHoid the fork tube upside down over a clean container
and pump it to drain the oil. Remove the rebound
damping adjuster rod (long) from the push rod.
A. Push Rod
B. Rebound Damping Adjuster Rod (long)
NOTE
o To discharge the fork oil, pump the push rod up and
down um tirmn.
Filling with Oil
BHoid the fork tube upright, press the outer tube and
the push rod all the way down.
Bl nsert both the long and short damping adjuster rods
into the push rod.
NOTE
o The spring Ihould not be inn.llild.
BFiIl the front fork to the top with specified oil.
BPurge the air from the fork cylinder by gently moving
the rod puller (special tool) up and down five times.
BPurge the air from between the inner and outer wbes
by pumping the outer tube up and down.
29
II
A. Outer Tube B. Inner Tube
NOTE
:JWhile doing this, take CIIrtI to kHp the oil level topPfJd
off so that it nays above the two ItKgtI holes neBr the
top of the inf1lH'tube.
1. Large Holes
2. Outer Tube
3. Inner Tube
CAUTION
Never axtend the fork fully, oil will be forced from
between the tube. into the Inner tube through the
hoi .. at the top of it. Thi. r. ite. the oil level In the
inner tube. If the fork I. extended to the full length
of iu normal trevel, the all ievel will be r. ised about
30mm.
Never Extend the Fork Fully
30
- After purging the air from the assembly. let it sit for
about five minutes so that any suspended air bubbles
can surface.
Adjusting Oil LweI
e Set the oil syringe (special tool), stopper so that its
lower side shows the oil level distance specified.
A. Oil SyrinJ!i: 570011290
B. Stopper
NOTE
o h t J U ~ tube is grlKiulJted in 1 em division.
o Th. IYringe body Is grsdutJt8d in 10 mL division,
excluding thfllJllUfJfI tube o( sbout-5 mL c.p:ity.
Recommend Oil
SAESW (KAYABA 01)
Oil Amount
See the SpecifiC8lions.
Oil level
o 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
oPos/tion the rtopper 80 that the gaufIB tube is pamllel
to and at the back of the Inner tube with the
handlebarr straight shud.
o PuIi the handle slowly. pumping out all excess oil.
*I f no oil is pumped out, there is insufficient oil in the
fork tube. Pour in enough oil, then pump out the
excess oil.
_ Install the parts removed (see Front Fork Assembly
in this chapter).
Fork Sprinll
Different fork springs are available to achieve suitable
front fork action In accOfdance with the rider's weight
and track condition.
_ Harder springs make the for k stiffer, and rebound
action quicker.
- Softer springs make the fork softer, and rebound
action slower.
Fork Clamp Position
Steering qualities are greatly affected by the fork
clamp position (the amount of the inner tube projecting
above the upper fork clamp). When the fork tube height
is smaller, the front end becomes lighter due to change
in weight bias. Also, it tends to understeer in turns and
"wash out". When the height is greater, the results are
opposite.
NOTE
oAfter adjusting the fork height, be lUre the front tire
doet not rub thfl fender when the forb compfftl fully.
Normal riding qua/itltlS are IIChkwed whfln the fork
tube top align, with the upper IUrftJCe of the upper
fork clamp.
The outllr tl.Ibes,
adjusted evenl y.
A. Tube Height
CAUTION
both right and lett. should be
Front Fork Removal (Each Fork Tube)
Front Fork Remonl
- Using the jack (special tool ) under the frame, stabilize
the motorcycle.
e Place a stand or block under the engine so that the
.. WARNING
lift the front wheel before unscrewing both top
plugs, or the front f9rk tube, will fully compress
causing injury or tipping of bike.
e Remove the following:
Front Disc Cover
Brake Hose Holder
Front Fork 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.
_ Remove the front wheel (see Front Wheel Removal in
the Wheels{Tires chapter).
e Release the air pressure from the fork.
_ Loosen the front fork top plug temporari ly.
- Loosen the upper and lower fork clamp bolts.
- With a twisting motion, work the fork tube down and
out.
A. Upper Fork Clamp Bolts
B. Lower Fork Clamp Bolts
Front Fork Installation Notes
e lnstallation is the reverse of removal.
31
e lf the fork tube was disassembled, check the fork oil
level.
e 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 spec-
ified torque .
- Install the front wheel (see Front Wheel Installation
Notes in the Wheels{Tires chapter). Mount the axle
clamps, and tighten the clamp nuts, first tighten the
upper clamp nuts and then the lower clamp nuts to the
specified torque. The arrow mark on the axle clamp
must point upwards.
A. Arrow Mark C. Lower Clamp Nuts
B. Upper Clamp Nuts
e i ~ t e n the front fork top plug to the specified torque.
e Tighten the handlebar clamp bolts to the specified
torque.
e Tighten the front fork protector mounting bolts to the
specified torque.
e lnstall the brake hose holder.
e i ~ t e n the caliper mounting bolts to the speCified
torque.
e Check front brake operation after installation.
elnstall the front disc cover.
Front Fork Disassembly
Spring Guide Removal
eHold the fork tube vertically, and unscrew the top
plug.
e Push the outer tube all the way down away from the
top plug and hold it there throughout the following
procedure.
CAUTION
Be careful not to damage the outer tube.
32
_ Pull the 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.
A. Fork Spring
B. Push Rod Nut
C. Fork Spring Holder:
570011286
- Use wrenches on the rod nut and the top plug to
loosen the push rod nUL
A. Top Plug C. Fork Spring
B. Spring Seat
e Remove the top plug from the push (od.
e Uft the fork spring and its top spring seat out of the
inner tube.
eTake the rebound damping adjuster rod (short) out of
the push rod.
B. Push Rod
- Hold the fork tube upside down over a clCOlfl container
and pump it to drain the oil. Remove the rebound
damping adjuster rod (long) from the push rod.
A. Push Rod
B. Rebound Damping Adjuster Rod {long)
- Remove the push rod nut, and take out the collar and
the spring guide.
A. Push Rod Nut C. Spring Guide
B. Collar (E2 Model only)
Pu.h Rod Di ..... mbl y
_ Hold the fork tube vertically with compression valve
up.
_ aean the bottom of the inner tube.
- Re move the cap on the bottom of the inner tube.
- Slip the fork cylinder holder (special tool) down over
the rod to engage the top of the inner cylinder.
_ While holding the fork inner cylinder from turning
with the special tool, remove the compression valve
from the bottom of the inner tube with an Allen
wrench.
_ Remove the push rod and inner cylinder from the top
of the outer tube.
3
1. Fork Cylinder Holder : 57001-1287
2. Cylinder Unit
3. Cylinder Valve Assembly
A. l nnerTube C. O-ring
B. Cylinder Valve Assembly D. Gasket
NOTE
000 not remove the inner tube from the outer tube.
A. Push Rod
C. Inner Tube
B. Inner Cylinder
_Unscrew the guide stay nut from the piston holder, and
remove the split ring keepers.
eRemove the O-ring, guide stay nut, oil lock piston and
piston holder from the push rod.
33
A. O-ring D. Oil Lock Pi ston
B. Guide Stay Nut E. Piston Ho.lder
C. Split Ring Keepers
.Putt the push rod assembly out of the bottom of the
inner cyl inder.
A. Push Rod Assembly
B. Inner Cylinder
I nner Tube Removal
- Separate the inner tube from the outer tube as follows:
oSlide up the spring band.
o Slide up the dust seal.
A. Spring Band B. Dust Seal
34
o Remove the retaining ring from the outer tube.
A. Retaining Ring
oGrasp the inner tube and stroke the outer tube up and
down several times. The shock to the fork seal sep-
arates the outer tube from the in ner tube.
e Remove the guide bushings, washer, all seal , retai ning
rin& dust seal from the inner tube.
A. Guide Bushings" C. Oil Seal
B. Washer
Front Fork Assembly
Innef to Outer Tube Assembl y
e Assembly is the reverse order of disassembly .
Replate the following with new parts :
Dust Seal
Retaining Ring
Oil Seal
Guide Bushing
. Place an oil coated plastic bag over the end of the inner
tube to protect the oil seats.
a 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.
- Slip a plastic bag over the fork inner tube upper end to
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.
_I nstall in order these parts on the inner tube:
1. Dust Seal
2. Retaining Ring
3. Oil Seal
4. Washer
5. Outer Tube Guide Bushing
6. Inner Tube Guide Bushing
7. Sharp EdF
8. Plastic Bag
_ When installing the new outer tube guide bushing, hold
the washer against the new bushin& and tap the washer
with the fork oil seal driver (special tool) until it stops.
A. Guide Bushing
B. Washer
c. Fork Oil Seal Driver:
570011340
e After install ing the washer, install the oil seal by using
the fork 011 seal dri ver (special tool) .
Inner Cylinder Auembly
_ Install the oil lock piston on the piston holder so that
the grooves face down.
OFirst, insert the push rod into the cartridF, then,
install the anti-bottoming piston. The hardened steel
keepers that hold the anti-bottoming piston to the
push rod can cause severe damage to the forlc if not in-
stalled securely.
1. Push Rod
2. Guide Stay Nut
3. Split Ring Keepers
4. Oil Lock Piston
5. Piston Holder
6. Upward pressure on piston holder positions keepers
while guide stay nut is tightened.
- ngnten the guide stay nut to the specified torque.
- Check the O-ring on the guide stay nut, and replace it
with a new one if damaged.
A. Piston Holder D. Guide Stay Nut
B. Oil Lock Piston E. O-ring
C. Grooved Side
35
Inlullinner Cylinder
- Check the O-ring on the compression valve assembly,
and replace it with a new one if damaged.
- Replace the gasket with a new one.
- Apply a nonpermanent locking agent to the threads of
the compression valve and screw the valve into the
bottom of the inner tube.
A. Compression Valve C. Gasket
B. ().ring
D. Threads
- Hold the inner cylinder with the inner cylinder holder
(special tool), and tighten the valve to the specified
torque.
-I nstall the spring guide so that the ronFr end is down.
Then install the collar with end down.

{
A. Longer End
B. Large End
36
_Screw on the push rod nut so that the chamfered side
is down.
oPosition the push rod nut at 18.5 rnm or more from
the top of the push rod.
}@)
n
1.18.5 mm
2. Push Rod Nut
3. CoUar (82 Model only)
4. Chamfered Side
S. Spring Guide
e lnsert the rebound damping adjuster rod (long) into
the push rod.
e lnsert the rebound damping adjuster rod (short) into
the push rod so that the holes are down.
B. Holes
_ Pour In the type and amount of fork oil specified and
adjust the oil level (see Oil Level Adjustment in this
chapter).
_Screw the fork push rod puller (special tool) onto the
end of the rod.
e PuIl the push rod up with the special tool for the next
procedures.
NOTE
OPuIl up the pulh rod "owly 10 as not to $pill the fork
all out of the fork tube.
e lnstall the fork spring into the inner tube and then set
the spring ~ in place.
_ Pull the fork spring down while pulling up on the fork
push rod puller (special tool) and insert the fork spring
holder (special too1) under the push rod nut.
A. Fork Push Rod Puller: 57001-1289
B. Fork Spring Holder: 57001-1286
_ Remoye the fork push rod puller (special tool).
_ Check the O-ring on the top plug, and replace it with a
new one If damaged.
_ Unscrew the rebound damping adjuster fully, then
screw the front fork top plug onto the push rod.
_ Holding the top plug with a wrench, tighten the push
rod nut against the top plug to the speci tied torque.
A. Top Plug C. Fork Spring
B. Spring Seat
_ Pull out the fork spring holder (special tool ), raise the
outer tube, and screw the top plug into it.
- Install the front fork (see Front Fork Installatioo
Notes in this chapter).
Inner Tube Inspection
e Visuall y inspect the inner tube, repair any damage.
e Nicks or rust damage can sometimes be repaired by
using a wet-stone to remove sharp edges or raised areas
which cause seal damage.
* If the damage is not repa irable, replace the inner tube.
Since damage to the inner lube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
e Temporarily assemble the inner and outer tubes, and
pump them back and forth manuaJly to check for
smooth operation.
CAUTION
If the inner tube i. badly bent or creased, replace it.
Exceuive bending, followed by subsequent straight-
ening, ~ n weaken the inner tube.
Guide Bushing Inspect ion
e Visually inspect the guide bushings, and replace them if
necessary.
A. Guide Bushings
Oil Sea/and Dust Sea/ Inspect ion
el nspect the dust seal for any silJls of deteriorat ion or
damage.
* Replace them if necessary.
e Replace the oil seal with a new one whenever it has
been removed.
37
A
B
A. Oi l Seal B. Dust Seal
Spring Tension
Since a spring becomes shorter as it weakens, check
its free length to determine its condition.
*If the spring of either fork leg is shorter than the
service limit, it must be replaced. If the length of a
replacement spring and that of the remai ning spri ng
vary greatly, the remai ning spring should also be
replaced in order to keep the fork legs balanced for
motorcycle stability.
Fork Spring Free length
.. ~ . -_.
38
.......................................... .. " ............................... ..
Rsar Suspension (UniTrak)
................ .... ............. .. .. ... ............. .. .. .. .. ..................
Rsar Shock Absorber:
Shock Damping Adjustment
Rear Shock Absorber
The location of rebound dampi ng adjuster is changed
as shown.
A. Rebound Damping Adjuster
Ga. Re .. rvoir
Gil, PressufYJ
B. Mark
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 condi-
tions.
Rear Shock Absorber Disassembly (Oi l Change)
- After releasing nitrogen gas, remove the air bleeder
bolt, and pump the rear shock to drai n the oil out of
the rear shock body and the gas reservoir. This makes
it easy to push the reservoir cap in.
"WARNING
Be .. re to point the ras . ..... oir valve from you wh.n
... Ieaslng nitrogen p . pre. ...... An oil milt is often
rel .... d with the nltrO{lln.
AlwlV' rei.... nitrogen gal prellUnI to prev.nt
expl osiv. t8p*r. t1on of paru.
Electrical System
..................................... ... ................ ....................
Exploded View
........................ ................................. .. ........... ......
................. ...........................................................
Wiring Diagram
.......................................... ..................................
I
I I I
l!'
>
n !

I
~ ~ ~ ~
f

> '!..
,
! .!

@
~
39
Color Code
'K
Black
G
G ~
0 Onlnge
R Rod
W White
V Y.llow
1. Spark Plug
2. Ignition Coil
3. COl Unit
5, Magneto
6. Pickup Coil
7. Excitor Coi l
40
............................................................................
Specifications
............................................................................
Item Standard
ISJlition System:
Ignition timing: 19' BTDC @6 000 r/ min (rpm)
Ignition Coil : Primary winding resistance 0.311) ' 15%
Secondary winding resistance 3. 1 kl)'15%
COl unit internal resistance
Stator coil resistance
Spark. plug: Spark plug gap
Ignition System
Ignition Coil Inspection
Ignition Coil Winding R istance
Primary windi ngs: 0.31 n 15%
Secondary windings: 3. 1 kO 15%
S.,.rk Plull G8p
0.6 - 0.6 mm
CDI Unit Inspection
_Make the measurements shown in the table.
COl Unit Test Using KIW.,.ki Hind Tetter
refer to page 40
refer to page 40
0.5 - 0.6 mm
NOTE
0Arterlsk ,.}: When ntpeBtlng the test indlated with an
4sterisk, wait for more than 30 minut8s before fl8xt
trilll to get II relisblt/ rt/sult.
Stator Coil Resistance:
Connection
Black/Whlte Black/Yellow
White/ Red - Black/Yellow
Range: x lOOn
Reading (20'C (68'F)(
153 230 I)
7.9 - 11.9 1)
Tester Positive (+) Lead Connection
Black/ White
Black/White Black/Yellow White/Red Black
Lead Color (Stop)
(Exciter)
(Stop) (Ground) (Pickup) (Ign. Coil)
c

0
Black/White
'" (Stop)
0
..-
-
..-
c
3
(Exciter)
'0 Black/ White
0

(Stop)
..-
-
-'
-'
I
Black/Yellow

(Ground)
3-' 3-'
-
..-

z
White/Red

II

15-2' 15 -2' 7-8
-'

Black
10 - 16 10 - 16 3-4

(Ign. Coil)
-
.... : Infinity Range : x 1 kn Unit: kn
SUPPLEMENT - 2000 - 2004 MODELS 11
Supplement - 2000 - 2004 Models
Table of Contents
Foreword ............................................................ ..................................................................... 1-2
General Information ............................................ ....................................... .............................. 1-3
Fuel System............................................................................................................................. 1-7
Engine Removal/ Installation ................ ... .. .. ..... .... ............. .. ................................. .................... 1-8
Engine Bottom EndfTransmission .......... .. ........... ........... ........................... .......... .................... 1-9
WheelslTires. ....................... .......... ................ .................... ................ ... ...... ..... .... ..... ............... 1 10
Final Drive ......................... .... ... ..... .... ... ....... ................. .... ...... ....... .. .. ... ........... ....... ..... ...... ... ... 111
Brakes ..................................................................................................................................... 112
Suspension..... .... ...... .... ..... ........................................ .................. ... ............ .................... .. ...... . 1 13
Steering ................. ............... .. .. ....... .......................... ........... ......... .. .. .. .... ...... ......... ..... ... .. ....... 115
1-2 SUPPLEMENT - 2000 - 2004 MODELS
Foreword
How to Use thi s Manual
This "Supplement 2000- 2004 Models" designed to be used in conjunction with the front part of
this manual (up to P.40) andior Base Manual 'SS KX12SIKX2S0IKXSOO Service Manual - Part No.
99924-1101-01 . The specifications and maintenance procedures described in this chapter are only
those that are unique to the KXSOO-E12- E16 models.
Complete and proper servicing of the KXSOO-E12- E16 models therefore requires mechanics to read
both this chapter and the front of this manual
General Information
KX50o-E12 Left Side View:
KX50o-E12 Right Side View:
SUPPLEMENT - 2000 - 2004 MODELS 1-3
General Information
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark plug
Port timing
Inlet:
Scavenging
Open
Close
Open
Close
Exhaust Open
Close
Lubrication system
Drive Train:
Primary reduction system
Type
KX500-E12
2 190 mm (86.2 in)
815 mm (32.1 In)
1 205 mm (47.4 in)
1 490 mm (58.7 in)
370 mm (14.6 in)
950 mm (37.4 in)
100 kg (220.5 Ib)
52 kg (114.7 Ib)
54 kg (119.1 Ib)
9.9 L (2.6 US gal)
! KE500-E13-E16
2-stroke, Single cylinder, piston reed valve
Liquid-cooled
86.0 x 86.0 mm (3.39 x 3.39 in)
499 mL (30.4 cu in)
7.4 : 1 (High speed), 8.3 :1 (Low speed)
47.4kW (64.5 PS) @7 000 r/min (rpm)
66.6 Nm (6.8 kgm, 49.2 ftlb) @6 000 r/min (rpm)
Carburelor, KEIHIN PWK 39
Primary kick
COl
19 BTDC @6 000 r/min (rpm)
NGK BR8EG (US) NGK B8EG I NGK BR8EG
Full open
60 BTDC
60 ABDC
83.5" BBDC (Low speed), 93.5 BBDC (High speed)
83.5" ABDC (Low speed), 93.5" ABDC (High speed)
Petrol mix (32 : 1)
Gear
Clulch Iype
Reduction radio 2.538 (66/26)
Wet, multi disc
1
General Information
Items
Transmission:
Type
Gear ratios:
Final drive system
1 sl
2nd
3rd
41h
51h
KX500-E12 I KE500-E13-E16
S-speed, constant mesh, retum shift
2.000 (32116)
1.444 (26/18)
1.181 (26/22)
0.954 (21/22)
0.791 (19/24)
Type Chain drive
Reduclion ralio 3.357(47114)
Overall drive ratio ,,6c..7'--4:..:6'--@=-:".::0"-p-'g"'e=ar'-___ -r:-=-=--=-=--::-::-__ _
Transmission oil: API SE, SF or SG
Type
Viscosity
Capacity
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire: MakefType
Size
Rear tire: MakefType
Size
Wheel travel
Wheel travel
Brake Iype: Front and Rear
Effective disc
Front
diameter:
Rear
SE class
SAE 10W30 or 10W40
0.8 L
45to either side
27
116 mm (4.6 in)
API SH or SJ wilh JASO MA
SAE 10W-40
DUNLOP K490 (EUR) DUNLOP D752FG, Tube type
80/100-21 51 M
DUNLOP K695 (EUR) DUNLOP 0752, Tube type
120/90-1966 M
310 mm (12.2 in)
Swing arm (Uni-Irak)
330 mm (13.0 in)
Single disc
220 mm (8.7 in)
190 mm (7.5 in)
Specifications are subject to change without notice, and may not apply to every country.
(EUR): Europe model
(US): U.S.A. model
General Information
Tighren all boits and nuts to the proper torque using an accurate wrench. If insufficiently tightened, 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 nut which is overtightening may become damaged, strip an internal thread, or
break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and
the parts requiring use of a 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 the specified torque.
Letter used in the "Remarks" col umn mean:
L' Apply a non-permanent locking agent to the threads .
Fastener
Torque
Remarks
Nm kgfm fHb
Fuel System:
Rear Frame Mounting Bolts (Upper) 34 3.5 25
(Lower) 34 3.5 25
Engine Removal/1nstallatlon:
Engine Mounting Nut (10 mm Oia.) 44 4.5 32.5
Engine Mounting Bracket Nut (8 mm Oia.) 29 3.0 21 .5
Engine Mounting Bracket Bolt (8 mm Oia.) 29 3.0 21.5
WheelfTlres:
Front Axle Nut 79 8.0 58
Final Drive:
Rear Sprockel Nuts 34 3.5 25
Brakes:
Caliper Mounting Bolls (Fronl) 25 2.5 18.0
Brake Hose Banjo Bolts 25 2.5 18.0
Front Master Cylinder Clamp Bolts 8.8 0.9 78 inlb
Rear Master Cylinder Clamp Bolts 7.8 0.8 69 inlb
Brake Di sc Mounting Svrews (Front, Rear) 9.8 1.0 87 inlb
Caliper Bleed Valves (Fronl, Rear) 7.8 0.8 69 inlb
Brake Pedal Mounting Bolt 8.8 0.9 78 inlb L
Suspension:
Front Fork Top 30 3.0 22
Front Fork Clamp Bolls (Upper, Lower) 20 2.0 14.5
Front Axle Clamp Nuts 8.8 0.90 78 inlb
Push Rod Nut 28 2.9 21
Guide Stay Nut 28 2.9 21
Front Fork Protector Bolts 8.9 0.90 78 inlb
Front Fork Cylinder Valve Assembly 54 5.5 40 L
Rear Shock Absorber Mounting Bolts 39 4.0 29
Tie-Rod Mounting Nuts 83 8.5 61
Rocker Arm Nut 83 8.5 61
Swing Arm Pivot Shaft Nul 79 8.0 58
Steering:
Steering Stem Head Nut 44 4.5 33
Steering Stem Locknut 4.9 0.5 431nlb
Handlebar Clamp Bolts 25 2.5 18.0
Fuel System
Exploded View
T1 : 34 Nm (3.5 kgfm, 25 ft lb)
T2: 34 Nm (3.5 kgfm, 25 ft lb)
Specifications
Item
Make/type
Main jet
Jet needle
Slow iet
Air screw
Service fuel level

I COI .... "
Standard
KEIHIN PWK 39
168
7
N82M
3rd groove from the top
58
2 (tums out)
-1.0 1 mm (-0.04 0.04 in)
(below the bottom edge or the carbo body)
Bore center 34 mm (1.34 in)
Float height 16 1 mm (0.63 0.04 in)
T1 : 44 Nm (4.5 kgfm, 32.5 ftlb)
T2: 29 Nm (3.0 kgfm, 21.5 ft lb)
I H ~ I O I I ' C
Engine Bottom EndlTransmission
Specifications
Item Standard
Transmission Oil :
Type API SE, SF or SG
API SH or SJ with JASO MA
Viscosity SAE 10W-40
Capacily 0.8 L
Transmission Oil
In order for the transmission and clutch to function prop
erly, always maintain the transmission oil at the proper level
and change the oil periodically.
Oil Change
Recommended Transmission 011
Type: API SE, SF or SG
Vi scosity:
Capacity:
API SH or SJ with JASO MA
SAE 10W-40
O.B L
NOTE
OAlthough 10W-40 engine all is the recomended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
-" ,
-.
,
-" ,
"
,
Service Limit
- - -
- - -
- - -
- - -
SA! 201 - 50
SA '
201 - 40
SA '
101 - 50
SA'
101- 40
SA'
101 - 30

" "
.. 40 ( '1:: )
, , , ,
1 ~ 4 ( F )
"
.. .. ..
, , , , ,
1101010111

WheelslTires
Exploded View
T1: 79 Nm (8.0 kgfm, 58 ftlb)
T2: 34 Nm (3.5 kgfm, 25 ftlb)
T3: 110 Nm (1 1 kgfm, 81 ftlb)
Specifications
Item Standard
Tires:
Front: Size 80/10021 51M
Make, type DUNLOP K490J (EU) DUNLOP D752FG, Tube type
Rear: Size 120/90-1966M
Make, type DUNLOP K695 (EU) DUNLOP D752, Tube type
Air Pressure (when cold) 100 kPa (1.0 kg/cm' , 14 psi)
(EU): Europe model
Service Limit
- - -
- - -
- - -
- - -
- - -
1

Final Drive
Exploded View
T1 : 34 Nm (3.5 kgfm, 25 ft lb)
T2: 110 Nm (1 1 kgf.m, 81 ft lb)
T3: 79 Nm (8.0 kgfm, 58 ft lb)
nOll l U " C
Brakes
Exploded View
A: KX500-E12 - E15 Models
S: KX500-E16 Model -
T1 : 5.9 Nm (0.6 kgfm, 52 inlb)
T2: 25 Nm (2.5 kgfm. 18.0 ftlb)
T3: 8.8 Nm (0.9 kgfm, 78 inlb)
T4: 7.8 Nm (0.8 kgfm, 69 inlb)
T5: 18 Nm (1.8 kgfm. 13.0 ftlb)
T6: 28 Nm (2.8 kgfm. 20 ftlb)
T7: 10 Nm (1 .0 kgfm, 87 inlb)
,
1
I L U I J I I ~ C
Suspension
Exploded View
o
o
o

8
T1 : 20 Nm (2.0 kgfm, 14.5 ftlb)
T2: 30 Nm (3.0 kgfm, 22 ftlb)
T3: 28 Nm (2.9 kgfm, 21 ftlb)
T4: 8.9 Nm (0.90 kgfm, 78 inlb)
T5: 54 Nm (5.5 kgfm, 40 ftlb)
T6: 83 Nm (8.5 kgfm, 61 ftlb)
T7: 39 Nm (4.0 kgfm, 29 ftlb)
T8: 79 Nm (8.0 kgfm, 58 ftlb)
L: Apply a non-permanent locking agent to the threads.
1. Shock Absorber Bracket
Suspension
Rear Suspension (Uni-Trak)
The rear susupension system of this motorcycle is Uni
It consists of a rear shock absorber, swing arm, tie-rod
and rocker arm.
To suit to various riding conditions, the spring preload of
the shock absorber can be adjusted or the spring can be
replaced with an optional one. Also the damping force can
be adjusted easily so changing oil viscosity unnecessary.
Turn the rebound damping adjuster [A] on the rear shock
absorber lower end with the blade of a screwdriver until
you feel a click.
*If the damper setting feels too soft or too stiff , adjust it in
accordance with the following table:
Seated position: adjuster turned fully clockwise [A] .
Rebound Damping Adjuster Setting
Standard: 11 clicks
NOTE
OAdjustment of the rebound damping adjuster for the rear
suspension will slightly affect the compression damping
force. Always make any damping adjustments in small
stes and test their effects before using them in compe
tition.
Tum the compression damping adjuster [A] on the rear
shock absorber gas reservoir with a flatbead screwdriver.
*If the damper setting feels too soft or too stiff, adjust it in
accordance with the following table:
Seated position: adjuster turned fully clockwise [A].
Rebound Damping Adjuster Setting
Standard: 10 clicks
NOTE
OAdjustment of the rebound damping adjuster for the rear
suspension will slightly affect the compression damping
force. Always make any damping adjustments in small
stes and test their effects before using them in compe
tition.
'"01000'" C
(Coun t erc l ock. i Ie) (C lock . i Ill)
Harder
+
1015 14 1312111011 ale 5 4 3 2 1
I- I I I I I I I I II I I I I 1. 1
(Coun ter c ' ock. i Ie)
t

I . OIDOli l l ,
(C lock . jlll)
Softer H. rder
+
181514131211101 ale 4 2 1
1" 1 1 1 1 1 1 1 1 1 1 1 1 1 1
t

unon." c
Steering
Exploded View
T1 : 25 Nm (2.5 kgfm, 18 ftlb)
T2: 44 Nm (4.5 kgfm, 33 ftlb)
T3: 4.9 Nm (0.5 kgm, 43 inlb)
T4: 20 Nm (2.0 kgm, 14.5 ftlb)
U O ' ~ l l 1 e
MODEL APPLI CATION
Year M:>del Beginning Frame No.
1990 KX500-E2 JKAKXVE10LAOO2001 or KXSOOE-002001
1991 KX500-E3 JKAKXVE10MAD04001 or KX500E-004001
1992 KX500-E4 JKAKXVE10NAOO7001 or KXSOOE-007001
1993 KX5OO-E5 JKAKXVE10PAOO8301 or KXSOOE-008301
1994 KX500-E6 JKAKXVE10RPD10001 Of KXSOOE-010001
1995 KX5OO-E7 JKAKXVE10SPD11001 or KX500E-011001
1996 KX5OO-E8 JKAKXVE10TPDl5001 or KX500E-015001
1997 KX5OO-E9 JKAKXVE10VPD17001 or KX500E-017001
1998 KX500-ElO JKAKXVECOWPD20001 or KXSOOE-020001
1999 KX500-E11 JKAKXVECOYPD23001 or JKAKXSOOEEPD23001
2000 KX500-E12 JKAKXVECOXI'D28001 or JKAKX500EEPD28001
2001 KX500-E13 JKAKXVEC01PD30001 or JKAKX500EEPD30001
2002 KX500-E14 JKAKXVEC02PD32001 or JKAKXSOOEEPD32001
2003 KX500-E15 JKAKXVEC03PD3SOO1 or JKAKX500EEPD35001
2004 KX500-E16 JKAKXVEC04PD37001 or JKAKX500EEPD37001
0 : This digit in the frame number changes from one machine to another.

Kawasaki Kx500 Service Manual Repair 1988-2004 KX 500

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