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

• Model application: covers 1998-2007 Kawasaki Eliminator 125 models BN125-A1 through BN125-A8, plus BN125A6F and BN125A7F, with beginning frame numbers for every listed model year.
• Document identity: a 385-page PDF, Kawasaki Motorcycle Service Manual Part No. 99924-1332-04, Ninth Edition (1), dated August 1, 2006, organized into 16 chapters.
• Fuel-system coverage includes MIKUNI BS28 carburetor removal, service fuel-level adjustment, disassembly, assembly, cleaning, and inspection, along with air-cleaner, fuel-tank, fuel-tap, clean-air, and California evaporative-emission service.
• Engine repair sections detail cam-chain tensioner and timing work, camshaft and chain service, cylinder-head and valve repair, cylinder/piston inspection, clutch and oil-pump work, engine removal, crankcase service, crankshaft, starter clutch, shift mechanism, and five-speed transmission repair.
• Chassis procedures cover front-disc and rear-drum brakes, brake-fluid change and line bleeding, master-cylinder and caliper overhaul, wheel/tire and hub-bearing work, drive-chain and sprocket service, fork disassembly, swingarm repair, and steering-stem bearing service.
• Electrical content provides five model- and market-specific wiring-diagram sets, DC-CDI and charging-system tests, peak-voltage procedures, starter-motor overhaul, lighting, switch, and relay checks, routing drawings, troubleshooting charts, torque tables, wear limits, and factory special-tool callouts.

Manual Organization and Content

This is the factory repair manual for the carbureted, air-cooled 124 cc SOHC Eliminator 125, not a generic manual for larger Eliminator models. The publication moves from general information and the periodic maintenance chart through fuel, engine, drivetrain, chassis, and electrical work, then closes with cable, wire, and hose routing plus system-based fault isolation. Most repair chapters open with numbered exploded assembly views. Their adjoining legends identify the fasteners involved and mark where engine oil, grease, locking agent, sealant, or replacement parts are required.

The manual reaches well beyond routine maintenance. Engine coverage includes compression testing, top-end removal and installation, valve-guide and valve-seat work, piston and cylinder inspection, crankcase separation and assembly, crankshaft and balancer service, starter-clutch inspection, external shift-mechanism repair, transmission-shaft disassembly and assembly, and bearing and oil-seal replacement. The lubrication chapter adds an engine oil-flow chart, oil-pump overhaul, oil-pressure measurement, relief-valve inspection, and oil-pipe service. Chassis sections address the hydraulic front brake and mechanical rear brake, telescopic fork, dual rear shocks, swingarm, steering stem, spoke wheels, tube-type tires, and chain final drive.

Model, Market, and Diagnostic Detail

Kawasaki's model-application chart matters because the code sequence does not track the calendar year in a simple way after 2004: BN125-A7 is the 2004 model, BN125-A8 is 2005, BN125A6F is 2006, and BN125A7F is 2007. Procedures and specifications distinguish A1/A2 from A3-and-later machines, A1-A3 from A4-and-later builds, A1-A4 from A5-and-later harness layouts, and later A6/A7 regional configurations.

Regional notes separate CA (Canada) from CAL (California) and cover U.S., Europe, Singapore, Austria, Switzerland, Germany, Italy, United Kingdom, and N/NU non-catalyst models. Those differences affect emissions equipment, carburetor calibration, final-drive details, brake and handlebar procedures, charging and ignition tests, lighting, wiring, and cable routing.

Reference graphics include the DC-CDI charging, trigger, and ignition-advance diagrams; coasting-enricher airflow drawings; the engine oil-flow chart; exploded crankshaft/transmission and brake/suspension assemblies; the five regional wiring-diagram sets; and variant-specific cable, wire, and hose routing plates. Electrical diagnosis covers alternator output, stator and regulator/rectifier checks, charging voltage, crankshaft-sensor resistance and peak voltage, ignition timing, coil primary peak voltage, CDI resistance, starter relays, AC lighting, and turn-signal operation.

Factory tools are identified by part number. Examples include Fuel Level Gauge 57001-1017, Clutch Holder 57001-1243, Bearing Driver Set 57001-1129, Hand Tester 57001-1394, and Peak Voltage Adapter 57001-1415.

The manual flags two easy-to-miss repair traps. The non-return cam-chain tensioner can be damaged by partial removal, and turning the crankshaft while the tensioner is out can disturb cam timing and damage the valves. During bearing press work, the crankcase bearing boss must be supported or the crankcase can be damaged. Fuel, battery, brake, and engine service should be performed with the motorcycle securely supported and the manual's safety instructions followed.