Kawasaki Eliminator 125 BN125 Service Repair Manual (2001–2007) – PDF
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Official Kawasaki Eliminator 125 (BN125) Service Manual covering 2001–2007 models. Includes engine overhaul, carburetor tuning, clutch and transmission service, frame and suspension repair, wiring diagrams, and full specifications. Perfect for DIY owners and workshop technicians maintaining or rebuilding BN125 motorcycles.
Description
Kawasaki Eliminator 125 BN125 Service Repair Manual (2001–2007) – PDF DOWNLOAD
Description
Overview
This Kawasaki Eliminator 125 Service Manual provides factory-authorized maintenance, troubleshooting, and overhaul information for BN125 models. It’s the same comprehensive guide used by authorized Kawasaki service centers, featuring detailed repair procedures, specifications, wiring schematics, and exploded diagrams.
Model code: BN125-A/B
Engine: 124 cc, air-cooled, 4-stroke, SOHC, single-cylinder
Fuel system: Keihin CVK carburetor
Transmission: 5-speed constant mesh
Main Sections & Coverage
1. General Information
Vehicle identification, model codes, and serial number locations.
Safety precautions, unit conversions, and service specifications.
Torque values, special tools, and lubrication charts.
2. Periodic Maintenance
Maintenance schedule for 600 mi, 4,000 mi, and 7,500 mi intervals.
Engine oil and filter replacement, spark plug inspection, air filter cleaning, and chain tension adjustment.
Valve clearance check and adjustment procedures (Intake 0.10–0.15 mm, Exhaust 0.15–0.20 mm).
3. Fuel System
Keihin CVK carburetor detailed service — float height (14.5 ± 1 mm), idle mixture, synchronization.
Fuel tank, petcock, and fuel line inspection.
Throttle cable routing and free play adjustment.
4. Engine Top End
Cylinder head and valve removal/installation.
Piston ring and cylinder wear limits (STD bore: 56.0 mm; ring end gap: 0.2–0.4 mm).
Compression test procedures and cam timing marks.
5. Clutch and Transmission
Multi-plate wet clutch service; spring free length and plate wear limits.
Gearbox disassembly and inspection of shift drum, forks, and transmission shafts.
Primary drive ratio 3.350 (67/20), final ratio 2.733 (41/15).
6. Engine Lubrication & Cooling
Oil pump and strainer service.
Crankcase breather cleaning.
Oil pressure test values and diagram of oil passages.
7. Chassis
Front Suspension: Telescopic fork (31 mm), oil capacity 158 ml per leg.
Rear Suspension: Twin shock absorber preload adjustment.
Steering: Bearing race torque and adjustment procedure.
Brakes: Front hydraulic disc, rear mechanical drum — pad/shoe wear limits and bleeding procedure.
8. Electrical System
Full wiring diagram with color codes.
Charging system specs (Generator output: 14V, 14A @ 5000 rpm).
Battery, starter motor, ignition coil, CDI unit, regulator/rectifier test procedures.
Lighting system, horn, and switch troubleshooting.
9. Troubleshooting
Quick-reference chart for no-start, weak spark, poor idle, or overheating.
Step-by-step diagnostic logic for electrical and fuel systems.
Compression and spark verification process.
10. Appendices
Complete Torque Table (frame, engine, suspension).
Special Tool Index with Kawasaki part numbers.
Wiring diagram foldout pages.
Technical Specifications
| Component | Specification |
|---|---|
| Engine Type | 4-stroke, single-cylinder, SOHC |
| Displacement | 124 cc |
| Bore × Stroke | 56.0 × 50.6 mm |
| Compression Ratio | 9.5:1 |
| Carburetor | Keihin CVK26 |
| Transmission | 5-speed constant mesh |
| Lubrication | Forced wet sump |
| Ignition | CDI |
| Battery | 12V 8Ah |
| Front Tire | 90/90–17 |
| Rear Tire | 130/90–15 |
| Fuel Capacity | 11 liters |
| Curb Weight | 145 kg |
Technician Benefits
✅ Accurate OEM torque specs and diagrams
✅ Step-by-step maintenance and overhaul procedures
✅ Wiring and electrical troubleshooting charts
✅ Perfect for both workshops and DIY mechanics
File Details
| Field | Description |
|---|---|
| Manual Name | Kawasaki Eliminator 125 BN125 Service Manual |
| Models Covered | BN125-A / BN125-B |
| Years Covered | 2001–2007 |
| Manufacturer | Kawasaki Heavy Industries |
| Pages | ~385 |
| Language | English |
| PDF Quality | High-resolution OEM scans with searchable text |
| File Type | PDF Download |
