Kawasaki Eliminator 125 1998–2007 Service Manual (P/N 99924-1332-04)

This 16-chapter factory service manual covers the 1998–2007 Kawasaki Eliminator 125, including BN125-A1 through BN125-A8, BN125A6F, and BN125A7F. It is the Ninth Edition (1), dated August 1, 2006 (P/N 99924-1332-04).

PDF Search, Bookmarks, and Wiring Detail

Finding procedures and diagrams: The service text is searchable, and embedded bookmarks lead to chapters, procedures, and specification tables. The small wire codes and switch labels inside the wiring diagrams are image-based and need zooming for comfortable reading.

The ZIP download contains one printable English-language PDF. The 385-page total includes the original front cover, title page, back cover with the model application table, 14 blank pages, and one labeled spacer page in the electrical chapter.

Carburetor, Engine, and Electrical Service

The selected topics below give an overview of the service and repair procedures. The manual also covers fork oil-level checks and frame inspection.

• Scheduled maintenance: A periodic maintenance chart and step-by-step procedures for oil and filter changes, valve-clearance adjustment, and clutch-cable adjustment.

• Fuel and emissions: MIKUNI BS28 carburetor removal, disassembly, reassembly, cleaning, inspection, and service fuel-level adjustment, plus air-cleaner, fuel-tank, fuel-tap, clean-air, and California evaporative-emission service.

• Engine and drivetrain: Camshaft, cam-chain, and tensioner service, cylinder-head and valve repair, engine removal and installation, crankcase separation, clutch service, and transmission repair.

• Brakes: Hydraulic front-disc and mechanical rear-drum service, including brake-fluid changes, line bleeding, master-cylinder and caliper overhaul, and rear brake shoe inspection.

• Wheels and suspension: Wheel and hub-bearing service, chain and sprocket inspection and replacement, fork disassembly, swingarm bearing service, and steering-stem bearing replacement.

• Electrical diagnosis: Five model- and market-specific wiring diagrams, DC-CDI and charging-system tests, starter-motor overhaul, and lighting, switch, and relay checks.

Kawasaki wrote this manual primarily for trained mechanics in an equipped shop. Owners familiar with workshop procedures and proper tool use can also use it for basic maintenance and repairs.

Model and Market Differences

The model application table lists the beginning frame numbers for each model. BN125-A7 corresponds to 2004, BN125-A8 to 2005, BN125A6F to 2006, and BN125A7F to 2007. Matching the frame number and market designation helps you choose the applicable wiring diagram, routing drawing, or service procedure.

Brake-pad and handlebar procedures differ between A1/A2 and A3-and-later models. Valve-adjusting cap and cam-chain cover torque specifications change at A4, and the appendix separates A1–A4 harness routing from A5-and-later layouts. The N and UK-market NU non-catalyst versions have different final-drive specifications from A7 onward.

The manual distinguishes Canada (CA) from California (CAL), with separator operation and canister checks for the California evaporative system. Market notes also identify differences for Europe, Singapore, Austria, Switzerland, and Germany. Italy is identified in the frame illustrations.

Engine, Lubrication, and Chassis Repair

Top-end procedures cover valve-guide replacement, valve-seat repair, and cylinder, piston, and ring inspection. Bottom-end work includes crankshaft and balancer service, starter-clutch inspection, external shift-mechanism repair, transmission-shaft disassembly and reassembly, and bearing and oil-seal replacement.

An engine oil-flow chart accompanies oil-pump overhaul, oil-pressure measurement, relief-valve inspection, and oil-pipe service. Numbered exploded views identify fasteners and show where oil, grease, threadlocker, sealant, or replacement parts are required. Specification tables give torque values and wear limits.

Chassis coverage includes spoked wheels, tube-type tires, and the telescopic front fork. Rear shock coverage is limited to leak inspection, preload adjustment, and removal and installation.

Ignition Tests and Shop References

The charging and ignition sections distinguish A1/A2 circuits from A3-and-later circuits. They cover alternator output, stator and regulator/rectifier tests, charging voltage, ignition timing, crankshaft-sensor peak voltage, ignition-coil primary peak voltage, and CDI resistance. The ignition troubleshooting flowchart helps separate wiring faults from crankshaft-sensor, coil, and CDI faults.

DC-CDI diagrams show capacitor charging, triggering, and timing advance. The coasting-enricher drawings show fuel and airflow during deceleration, and the appendix provides cable, wire, and hose routing drawings and symptom-based troubleshooting.

Factory tool references include the Fuel Level Gauge 57001-1017, Clutch Holder 57001-1243, Bearing Driver Set 57001-1129, Hand Tester 57001-1394, and Peak Voltage Adapter 57001-1415.

Retightening a partly removed non-return cam-chain tensioner can damage the tensioner and chain, while turning the crankshaft with the tensioner out can upset timing and damage the valves. Pressing in bearings without supporting the crankcase bearing boss can damage the case. Follow Kawasaki’s safety precautions and support the motorcycle securely during service.

Selected Compression and Ignition Specs

The cylinder-head chapter gives a usable compression range of 960–1,470 kPa (139–213 psi) at 500 rpm for a warmed-up engine with a fully charged battery. A diagnostic table covers readings outside that range.

The ignition chapter lists crankshaft-sensor resistance at 180–280 Ω for BN125-A1/A2 and 190–290 Ω for BN125-A3 and later.