1982-1991 Kawasaki KX125 Service & Repair Manual

QUICK REFERENCE DATA MOTORCYCLE INFORMATION MODEL:, ____________________________________________ YEAR : __________ __ VINNUMBER: ENGNE SERIAL NUMBER: __________________________________________________ __ CARBURETOR SERIAL NUMBER OR ID. MARK: Front Ra"r EngIne 011 Tran,mlsslon oU API Classification 1991-1999 20<10-0. Fronllonc all 1982·1983 , ... 1985 , ... 1987.0" Air filter Drfvechlln Brake fluld F~I CoI"trol cables Mode' 1982-1983 , ... 198500n aeacti". (In •• IIGna) .. , , .. , ., , .. 1':1 ••• • •• 12.0 16 .0 TIRE INFLATION PRESSURE 100 kPa (14 psi) 100 kPa (14 pal ) R£CO .... ENDED LUBRICANTS AND FUEL Kawasaki 2- strcHte riel ... " 011 SAE 10WI3O or 10W/ 4t1 oU SE SE, SF, SG (5H , SJ with JASO MA) KYO G·1D Of' SAE 10 10 wt . 10W120 10 wt. 'wi. Foam Ilr IIUer all Chain lube DOT> Premium grllde-nl_rdl octane 90 or hi gher c.~ lube FUEL/OIL PREMIX RATIO Premix ratio 20:1 30:1 32:1 FUElIOlL RATIO (IN GALLONS, Alltlo (ounce. of oU-' 20:1 24:1 28:1 32:1 40:' 3.' ' .7 ~3 ' .D , .. ••• 5.3 • •• ' .D ., ••• ••• ••• 5.D ••• 12 .8 10.7 9.1 ' .D 5.' (continued) IX 50:1 " ' .5 3.' 5.'

FUELJOIL RATIO (IN GALLONS) (contlnuR) O' • ...,lIne Ratio lounc •• of oil~J Ilnplion., 115:1 2&.t 24:1 28:1 32:1 4<>.t 50:1 ... 20.' to.. 13.3 11 .• ,~. ••• .. 3.' 24.0 lli1.2 16.0 13.7 t~. S .• 7.7 3.5 28.0 22.. 18.7 '6.0 1• .0 tt> • •• ••• 32.' 25,6 21.3 11,3 1M 12.8 10,2 ' .5 36.' 28,8 24,0 20,8 18.0 14 .• 11 .5 5.' 40,0 32.0 26.' 22 .' 20.0 16.0 12.1 'Rounded to the closest tenth FUEL/OIL RATIO (IN LITERS) O.aollne Ratio {cc(a)jml(a) of 011"1 (In lit.,.) 16:1 20:' 24:1 28:1 32:1 4<>.1 50:1 , .. m 100 93.3 71 .4 '~5 SO 40 3.' 187.5 tSO 125 107,1 93.' 75 .. ••• 'SO ,.. 166.7 142,9 125 100 ao 5.' 312.5 "" 208.3 118,6 153.11 t2' '00 ••• J7' 300 "" 214,3 187.5 150 120 7.' 431.S , .. 2Ql .1 250,0 218.8 175 14' 8.' 500 400 333.3 215,1 "" 200 160 ••• 562.5 ... 375 321.4 281 .3 225 tao 10,0 .25 500 416.7 357,1 312.5 250 ,.. 11 .0 687.5 .'" ....3 392.9 343 .' 215 220 'Rounded to the closest tenth, FUEL TANK CAPACITY Modo' U.s. gel . Ut ... KXI25 1982·1983 2.' 7.' 1984 2.1 8.' 1985-1987 2.' 7.' 198&-1989 2.3 8.7 1990-1991 2.2 ' .J K"'SO 1882 2.' ' .1 1983-1986 ~t ••• t88' 2.' 7.' 1888 2.' 8.' 1989-1991 2.' .. , "" ... 1883 , .. ' .1 1884 2.7 10.2 lV85-1986 2.' ••• , .. 7 2.' .. , 1888-on 2.' ••• X

IIodel KX125 1982-1984 1985-1987 '988 1989-1991 KU50 • 8" 1983-1984 1985--1991 KX ... I,.,..,. 1982·1989 model. 1990-0n model. KX12S 1982-"'83 .984 1985-1989 1990-1991 KX250 1983-1984 1985-1991 KXSOO ...... , M .... ' KX125 KU50 KX500 II ... d. 1 KX125 "182· 1(187 198&-1991 KU" 1982·1986 • 987 1988-1991 KXSOO '983-on CLUTCH/TRANSIIISSION OI L CAPACITY cc 550 ... 6 .. 700 ... 700 800 000 FRONT FOAK OI L SPEC IFICATIONS See Tabie 7 on page 1().t See Tabll 9 on pegelOS COOLANT CAPACITY Llte rl 0. 70 0.90 0.88 0." I." 1.1 ' .3 SPARK PLUG TYPI: AND OAP See Table 14 on p89f1 107 5eeTabl e 15 on page 107 SeeTa bl e 16 on page 108 ou nce. 18.6 20.3 22.0 23.7 3Q.4 23.7 27.1 27. 1 .' . 0. 74 0.95 0.93 ' .0 ••• ' .2 1.4 CARBURETOR PILOT AIR SCREW ADJUSTMENT Tum , I'Mft . 1112 1112 • 1112 1112 • The 'lock carburetota on these model, WIIH8 not equipped with. pilot .Ir 1ICreW. x,

DRIVE CHAIN LENGTH MEASUREMENT- Standard W.ar limit mm (ln.1 mm I/n., KXIZ, 1082- U187 317.5 (12.5) 323 (12.7) '988 307.5 (12.1) 314 (12.4) 19a9...99. 317.5 (12.5) 323 (12.7) "X250 '982-1ge7 317.5 ('2.5) 323 (,2. 7) 1988-1991 317.5 (12.5) 31. (IU) "'SOO 1983-1987 317.5 (12.5) 323 (12.7) 1988-1991 317.5 (12. S) 314 (12.4) • 20-11011 length: &Nt.xt lor measurement procedures. DRIVE CHAIN FREE PLAY Mode' mm 'n. '982-00 1.96-2..36 REAft SHOC:;K A":lOR.Eft NITROGEN P'ftESSUR£ Year Stancillnl Mlnl""'m M •• lmum ktlc:m 2 Ip~1 ktllcm:t (pall kg/cm J (pal) '982-1!J85 . . . " .. '0.0 (JlI2) 10.0 (142) 15.0 (113) 1987- 1990 12.0 (170) 10.0 ('42) 15 .0 (213) '09' KX l2SIKX250 10.0 (.42) 10.0 (142) 15 .0 (213) 1991-on KXSOO 10.0 (1.2) 10.0 (142) 15 .0 (213) • Not ."eclfled . M .... NTENANCE TORQUE SPECIFICATIONS • om ft.·lb • Font tube plnch bon. KX,25 198,2· 1988 '" " '98' U.S. and taMet. " " All other UP .... " " Lower 20 15 199()..,99' '" 15 KX250 " " .XSOO '" 15 (continued XII

MAINTENANCE TORQUE SPECIFICATIONS (contl nued l Nom ft .·lb . Pushrod nut :ro 15 Rear u;le nut .. 72 Cylinder hHd nuls 1982 KX250 35 26 All au. model' 25 .. Cylinder head bolts 25 .. Spark plui' 27 30 011 drilin plug ''''' '3 115In"'b. ,983-0" :ro 15 Cylinder coolant drain boll 15 11 XI II

CHAPTER ONE GENERAL INFORMATION 11m Cl ymer ~hop manuu] co'>cr, 311 1982-1991 KX125 JIIU KX2."O and all 19!O!LW04 KX 500 KawJ\<lki mollk:ru .. , bl\"e,_ Tmublc,hon[mg. tunc-up. rn,llntcllance and fe- p,nT an.' not (lifflcuh. if you i..nnw what 1 00 " and eqUIpment In U\C <lnd whitt (0 do. Slcp-by·qcp in- 'Inu.:tion, gUide you through Joh .. rangmg from sim- pic l1l.uIlICnan(c III cmnplclc engme and "u'JX'n,ion mcrhau] TIll' manual h'l\ heen \pt.'cilio.:ally \4rillcn fm lhe amateu r hUIll!,' rl1!,'~'hanic The IC~I " complete enough. hO .... CH·r. for u-.e hy rr(lfe"lOnal mechan- 1(, I-or c\arnpk. engine ... en in' mclude .. t>a~il re- p'IIT inhlfJIhllWn ,1\ .... dl ,1\ t:umplele engine mcrh,1U1 and cmni..,h.l]t rchulldmg. All procedure... lahle .. , photo" ell: . 111 lhi~ manual a"ume that lhe rc;ukr mOl) Ix- workmg on Ihe hil..e ur u" ng Ihi\ manual for the fir\ttlllle. Thh 'oCc lion i\ included 10 acquainl Ih e horne mechanic wilh "hat i\ in the manual and how W I.j!..c be\\ ad\'anugc oflhe information For the most freljucnt ly u.... ::d genei.jl in formation and llIallilenance \pccificalioll\ rcfer \I) thc Quick RejeTt'II<'t' /Jaw page, For a hcucr undcl'\tJndlllg 01 manual con lcnh refer 10 /!IlUlIwl ()rgmJ/:llliol1 In [hl\ chapter. To \a\-e )uur-.clf tIlTlC. energy and 1X1\'lhk fUiure aggnl\al lon. lini\h rcadlllg Ihi., enllfe chapler. If )'OU acqu.unt )'ou~lf \.\. ilh ,-,lithe ,pcclallc.jture\ of thi \ manuallll'an benullc;l \.-alu,thk and IIld"pcn~3ble \001. 11m milnu,ll can help I1MI.C ) Il-Ur repair. more sUcce,,'ul and your m.H;hllle belief 1Il'lIn l'lIllCd • .lIld race ready. Tabl e I ii ..... lIludel numhcr<> and \en;.1 number. •

2 Tuh le 2 li~~ ~I.'ight "pt.."CificatiOll'_ Table 3 Ii,,, gcncr.tl torque ~pt.'t:lfic"'lion" L''>C Ihl' table a~:1 gencrJl ~uidclinc If a 'pcclfic IOrquc j .. nnt prml dcd. Table " Ii .. ,,, ~·on\<cr.ion fu n nu ' ;" Tab le 5 I'\h Iet:hnlcal abbrc\ 1.llIon" "liable 6 1i .. 1~ metric, Inch and IrJulonal eqUI\;l knt, Tuh le 7 Ii ~h metric I:.p and dnll .. i/c". MANU,\t ORGANIZ \ TlON " 11'11\ ch:lplc r prOVide" gcncrJl lnformali on u .. elul to KJ.\.I,,,,,;u. ;.i o\\n~'r\ and mcchaIl1C\. ln addition. in- lomlallon III Ih." chapter di<,Cu\\oC, the tool .. and technique .. for prc\CnlnC marnlcnanl;C. trouhll'- ,hooung anti rep.l lr Ch;Jpt~ r Two pruvidc, method, and <,uggc .. lilll\\ for qui d. and at ' CUfi ,tc diagno .. j, and rep<ur 01 proh· km .. Troublc,hoolrng procedure, d,,,-'u,, I)pn:al ,)mpIOim and logical melhod~ to prnpmnl lhc 1rt)U- hie. C'll;Ipter Thrce np lam<; all period it lubr ic.UlOn and mutlne lIlaimcnanee necc~~ury 10 I- eep }\lUr K, I "a'Jki operallng "cll. ChJplcr ThrL"C 011 .. 0 HI, dudc, re..:ommended Iurle-up proccdure,. climln.1I Ill!! the reed 10 ..:tJII~I 'llllly eon,ult othcr (haptcr. on Ihe \.Inou .. a~,cmhllc'. Su h'l'q ucn l cha ptcrs dc~nihe 'pecifie ~Y'· Icm" prO\iding di,u,.,embly. rep'lir. a\'>C'rnhl~ and adju~ t me"1 procedure, rn \rmple 'Iep b) 'Iep form If a rep:lir i, ImpTJCliGl1 for ~ horne me..:hamc, II " '0 indl(.lIcl.l. It i, u,ua ll y ta'lcr ,Ind Ie .. , c)(pcm,lvl' to I: II- l' ,\ \l o.:h rcp: lir .. t o:1 de .. ler or compe tent rcpa ir ,hup, Spccifitat lon, c()n..:erning a 'pcc l fil.: v}.'.Iem Me mduded Jt the end of the approprtall!' Chuptl!'T NOTES. CAU TlO'lS , 1\]) \\ ARNINGS Thc I crm~ NOTE, CAUT I ON Jnd WA RNING haH' .. peci fk mCJnllll!" in (hi, manual. A NOT !:. prm, id('~ addll illll .. 1 IIlfonnation to mill-l!' a 'tep or pnJl;ellurc ea' ICI III dC<llcr. Dt,rcgan.hng .. NOTL ..:nuld cauo;e IIl( 'OO\CllIcnce. but "nuld not ('au,,: damage or pef'tOnJI II1Jul). CIIAIYI'ER ONE A CAUTI O~ empha!ollc, area~ where equipment damage could occur. Dmcgartling a CAUTION cou ld e3u,e pennancnl rncchanu:al damage; how- cvcr, per;onal injUry jv unlll-ely. A WA RII.J ING empha,i/e, area~ where per;onal II1JUI}' or even death could rc,uh from ncgligcn(c. \1cchanlcal damage may al<,() ocl:ur. WAR~I"GS ur~ to ~ lu!en suiollsl\'. In varne C3!)e'. '>Criou~ injury and death has rc,uhed from di~rcgardjng !>imi lar wliming'. SArEn FIRST Prorc~\ional mcchanin I:an worl... for year!> and nc\'er ~u!'lain a \CriOU\ inJUry. If you ob'oCr\>c a fe" rule$ of common ..en .. c and ,afel). YoJU I.:an enJoy mall)' 'afc hOUT\ \Cr.il:ing }ourov.-n mJl:hlllc, If )OU Ignore Ihe,e rule\ you I:all hun )'our;elf or damagc lhe equipment I. ~e\'er u..e J1,a:.olinc a~ a dcaml1j!. \01\'cm. • CD

GENERAL I~FORM AT IOi\ 2. Never ~moke 11T u,{' a [orcn in [he vicinity or nammahlc Ii(IUid,. ,>uch a.~ cleaning solvent, in open contamer<.. 3. II" ",eldinS Qr 1.1larillg h n:YUIn:U un [lie m,lChinc, remove [he fuel tnn~ to a safe di~lUncc . al Ica ... 1 50 fcc[ away. 4. Usc the proper . izcd wrenches to aVOId damage [0 fa,\encr.; and injury to yourself. 5. When lomcntng.a tight ors(Uck nut. bcgutdcd by what would happL'Il if the wrellch 'Ihould ~hp Be cardul; protect your,elf accordmgly. 6. When replacing a ra,tencr. n[3ke slire 10 u~c one with the same mca~ur('ments and strength as the old one. Incorrect or mil>matchcd fa.stene~ can re..~uh in damage to thc 1ll000rcycie and possible perliona! injury. Beware of fll.'>tcner kil~ thll! arc filled with cheap and poorly made nuts. bolts. washcrl> and colter pillS. Refer to Fa.I/l'IIl'rs in this chapter for : Iddilicma l infonnatlon. 7. Keep all hand and power tools in good condi tion. Wire gre3~y and oily tool~ afler using th em. They arc difficldl to hold <lnd can cause injury. Re place or repair worn or d:lm<lgcd loo l ~. fl. Kec p your wor~ arca clean and unduuercd. 9. Wear ,alety gogglc~ (Fig ure 1) dunng all opera- uon .. Involving dnillng. gnndmg. lhe usc of a cold chi~el or (I/IVIIIII(' you lee l unsure about the sarety of your eye .... Safety goggles should al~o be worn any- ( \ ,"-. 3 lime solvent and compre\sed air" used 10 dean. pans. 10. Kccp an approved lire cXlingulshcr ( Figurt' 2) near )"our "'orkbcnch Wld in Jour lOW vdllde "hih: at [he mce track. Be sure il i~ ml ed for gU:'OllllC (Cla~, B) and elcctrical (Class C) lires. II. When drying bearings or other w[,lling p.lrb willi c(Jmpresscd aIr. nc\'cr allo" [hc air je[ I() rut'lIC the bearing or pari. TIle air Jo![ i, capiLhlc (Jr rmalin!,! them a[ speeds rar in excess ortho~{" for "hidl [hc) wen: dc~igncd. The bearing or rOluling pilf! i\ vcry likely 10 disintcgmte and cause scriou~ injury and d<llllage. To preve nt be' lring damage whcn using compresl;cd air. hold lhe inner bearing face by hand (Figur e 3 ). SERVICE IHNTS Most of the serv ice procedure~ co\I:red are straIghtforward and can he pcrfomled by anyone reasonably handy I'.[th toob. It IS ,uggeslcd. how- ever. Ih:1I you cO/1side r your own cap.lbilit[c\ care- lull y belore alletnpllIlg any operation irwolvtng major dIsassembly. I. ··Front .. · a ... u~cd in this manual. refer .. to Ihe frofU of the mOlorcyclc; the lroll! 01 any componcnl is the end clo~e~t to thc fronl o lthc llIolOrcyc1c. -ll1e "Iefl-" and "right -hand" SIdes re f cr 10 lhe positIOn of the puns as viewed by a nder smmg on the ~cat and faCing forward. For eX:implc. thc throl1lc c(lllirol i\ on Ihc right -hand ~Illc. Thc~c rules :Irc "mple. bUI confu.'>ion ca n cause" majOr incomclllcnce dunng service. See Figure 4. 2. When disas~ernbllflg any cnglllc or dnve ,'01111>0- nent , nl.lr~ Ihe pan~ for location and mark all pam I'.hich matc together Smull pan~. such :1' bol1~, t an Ix- idcntilied by placlIlg thcm in pla ... t lC ~an(\wlch bags (Figure 5). Seallhe bag~ and label Ihem W[lh ma ... ~ing [ape .. null nmrl:.1I1g pell. When rca.'>scmbly willlilke pl;lC~ immedillicly, an accepted practice i~ to pl.tcc nul!> and boll:. in a cupcu~c lin (Jregg canon in t he oldcr of dh""cll1bly. 3. Fil1i~1tcd ... urral.:c~ should be proleclcd Irom phy~r- cal d,tnJ.lge orl.:orrmion. Keep ga~()line on' painted "u rface~. 4. Usc penelraling 01 1on rrozen or light holl ... then strike Ihe bolt head il few tl!I\C ... with a hammer and punch (u~c a ~cfew drivl'l Ull screw,, ). Avoid Ihe usc of heat where possible. a .. il Cilll I'. arp. mell ur afTecl

(he tempcr 01 r:1n!>. lI enl al"" rum~ finishc). espe- ciall) paint and pht!>tic!>. AdditIonal mformation on removllll; frOlen fa!>tener .. , repairing l>( ripped IIm:~u~ .IfId reIn." inE broken bol" and 'K!TCWS I:. de,albed ulldcr \/ ,·,1!(lIlII·.fTir·\ In tlu~ chapter. 5, 1\0 p.ln .. rCIlIII\CU Of 1I1\I~llcd (ollll:rlh"o bushing) .md 1x-.mIlS') in Ihe proceuufC' gl\cn 111 Ihis manual ,houll.! n .. 'llullc 1Il1u,ual fon:c dunng dl~Obscmbly or J''Il-"lIIbly. If J I/,In I~ Ihffil,;ull 10 n:move or install, finl.! out "'h) befme pm .. :ceding, 6. COl'er ,,11 opcllIng' "fter rcmovmg pans or com- ponenb 10 pre\o:nl dIn. \nlall 1001 .. , elO:. from falling '" 7. Read each procc.'durc (·Oll/fllt'ff'I.\' while looking:1\ Ihe actual pan, before ~lllr1ing a job . Male ~ure you Il!w(mglll" un<.lc~[and .... ha\ i, to be done and then careful!), (olltlw lhe proc-cdul"l'. \\CP by ~lep 8. RecommendJII!1n, arc occa!>lonlll) made 10 refcr ,;el'\H.."\' or maintenance to a Kn\o\a. \aki dealer or" ,!X-ctnli,1 III a panicul"r field In Ihese case,. the \o\ orll. will he dOlle more quid..!y Dnd economically than if you pcrfonncd til;: jC1b )ouhclr. 9. In pro.:,,·dur'..ll ~ICp~. Ihc Ic nn ··rcpl :l("c·· me.:m~ to di'~'ard a dclecli\'e part and rcrl:1l"l! 11 \o\lth a new or .. ,"chan!!/,' uml "Overhaul" mean, to remov~. di~a,· ""mble. In"pect, me;l\urc, r<.'1);lir or repl:.ce defecll\C pan" rca"ernble and in,t ;1 11 major ,y,tem, or pan, 10, Some upcr,uicr" rC<.julfI: the u~e uf II hydmulic pre,",. It \~ould he v.1 .. cr 10 have Ihese opcmtions pcrfonn..-d by a ,hop rqulpped for s uth work. mlher Ihan to II) 10 do the Job )our.clf wuh makeshift equIpment thaI may danut~e your rnochine. ........ LE" CHAI'TER ONE II. Repai rs go much f:l,lcr and e:blcr If )'Ollr ma· chine is clean before you begin work. lllrre arc man)' special cleane" on the mancl, like Bcl -Ra} De!!reascf. for .... a!.hiTl!! the engine;,ll1d reilled pan .. Follo\o\ the manufacturer's direclion~ on lhe con· tamer for (he be~1 rc,ul". Oean : 111 oily or ~re"s) pan!, with c\ealling ,olvenl 3\ ),OU remove lhem U,\RNI"·G Neier usc' t:(/Jolmr us fA drani"~ O,I/rlll II p,-csnIU WI (·l/r('",1' firl' h(l:urlJ 8 1' $1.'-1' /() 1I'1l'-.\. 11/ 1I M'(·II·\'Ollillllftl art'IJ M'lten 1I001f? d"lmm.~ m/l'l!lll. Kup I1fi,., rXl/f/gllislJer, ralt'lJ for gl1.\(,lilll' fin':!'. h(md\' ill all\' l'lISI.', 12. Much of the labor chMges for rcP:UI1 made b) dealers are for the time imolved dunn!! in Ihe reo moval. di,asscmbly. :mcmbJy, and rein!>tallallon of olher [Ian:. in order to reach the defective pan. It is RIGHT _111!.~

GENERAL INFORMATIOi\ frequcllIly po~slblc [0 pcrfoml thc preliminary op- CrJ[iOh }olJr!>elf and then [akc [he defeclive unillO the dealer for repair at considerable saving». 13. If splXial tool, Me required, male amngcmenl.~ to get them bcfort )"OU ~Ian. It is fruSlr.!ling and time-con<,uming 10 ge[ panly into a Job and then be unable [0 complelc 1\ 14 Makc diagr:lm~ (orlake a Poluroid picture) wher ever ~imllar_~ppc:lJ"in£ parts are found. For in~(ance. rr:.lr1lClse bolt, are ollen not (he '>arne length. You may think )'ou can remember .... hcre everylhing came from- but mi<'lake~ are co,lIy. 1111~re is :lIso Ihc jl(l',,;hlhl) Ih:ll you may be "idetr.ICked !lJld nOi relum to .... orl for dJ.y~ or C1;cn y,ce\.:~ Ln .... hich Ihc lime carcfull} l:ud out pans may h:lVc become di, lurhed IS. \Vhcn ;c,~elllblmg parts. be sure all ~h ims and wa~hcrs arc Icpl.u.:cd e.\.Ktly as Ihey l.;.ulle OUI. 16. Whenever a mldltng pan buli\ agaln\t a 'Ialion- af)' pan. look for a ~h im orwa.shcr. U\e new gaskets If there IS lilly doubl about the condition of lhe old onc~. A [hill coal 01'Ilteone seal(1Il1 on non-pressure Iype ga~ket\ may help them seal moreeffecllvely. 17. When In\tailing engine ga ... keh. always use Kav. a~ki rcr1acemenlga~kel." I< I/hoUf\calcr, unless 'JX'cilicall) dc\ignalcd III [he [ex!. Ka""a!>aki gastels arc designed 10 ,well when 10 con tact wilh oil Ga,kel scaler prevcnl~ Ihe gasket,> from -"wc lling as Intended. whidl call result in oil leak .... Kawasaki ga,kel\ arc aho cut from material of Ihe precise Ihlckncs:. needed In ,t<l.l1alion of a 100 thick or 100 5 thin gasket in a critic-.tI area could ca u ~c engll1c damage. NOTE /) you' r/' In (j JlIm 1II1d vlllr {Ira/a {Joel IIor lillI'/, /hl' {'orrt'fl ,~uft('/ , Will !1m purchase .~U.f~('1 mawr/al fmlll an a/lto- lilli/II'/' fJ(lr!.\ storf' tJn(/ mof,;/' {/ ~(I\~l't lI 'juII pltrc hCl.lHl,i: gu~k('1 IfWlt'IUlI, ml'oslU"l' Ih(' Ihict"eu (If Iht' (1M S;U:lI..l'f (111(/ plln'huft' NUI ' kef miller/al 10·/,11 lilt' Wlnlf ol'pmHnllllf' ,h"l..m'.I$ Do 11(1/ (If - tt'mfll to mal..eu '1'"la('('/I('IlI h"{1l1 xm- 1..1'1 "'illt Rusl..", mllferwf. IK. Ileavy grc~ can be u~ed 10 hold \m:tll PJn~ in place If they lend \0 f:lll OUI during a~'o\Cl1lbl)'. Ilow- ever, keep grea~c :lnd 011 away from ckctncal com- ponent'. 19 . A carburetor I~ best cleaned b) di,a.."etnbling II and waking !hc pans In a commercial cMOOrelor cleaner. Ncver soak ga~lel5 and rubber parts In the~e clcaners. Ncver u\e wire to clean ou t JCI\ :lnu air passages. TIlcy arc ca,dy dJlTlagcd . USCCOn1prc~\cd air 10 blo .... oul Ihe earhuretor only if the nOa[ ha r., been removcd Ii",!. 20. Wlx!-n installing lhe '"(old-ovcr" type lockmg .... ashcr~ always u,e a nc"" wa ... hcr If po"lble:. If a new wa<.hcr is not ;!\'aIIJb1c a]""ay:. fold-o~cr a p.tn of tlx!- washer thot has nOI been prcvioo,ly folded. Reusing the same fold may cause [he ""asher 10 break. resulting in a loose pieceofmelal adrift In the engine. Whcn folding thc wa~hcrO\cr. \Iart the fold ...... llh a screwdri\cr and finilh It wllh a PJlrof plli.. .... ~. If a punch orchLsd i~ used to make the fold. the fold lIlay be too ~ harp. thercby Increasing Ihe chancc, or the w<l~hcr brcakll1g undcr "tres,. IlCCllU~C Ihc~e wa,hc,..., arc inexpcn ~lve, it i\ /ccommcndcd 10 kt~ep ,cvcr .d on hand. 21_ Take yoortime and do IhcJobnght, Do nOI forgel that. newly rebuilt engine: mU\1 Oc brokl'Tl In JU\! lilc as a new onc. ENG INE OI)ERATION All K3WasaI..J KX modcl~ are eqUipped With 2- stroke engines. Durmg Ihis dl!.cuhion. assume that the crankshaft is rol:ltlllg coun tcrcl oc k w i ~e III fig - u re 6 As thc pi'lon ir.wd .. d01.O.nward. a tr.m~fcr port (Al helwccn Ihc crankCfl,e lind the cylinder 1\ un covered The exhall~1 gMes Icave the cyhndcr

1982-1991 Kawasaki KX125 Service & Repair Manual

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