Z125 PRO

Foreword
In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most
commonly removed parts have a direct bearing on a vehicle’s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims
and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual explains step by step procedures of the following
items for all Kawasaki Z125 PRO.
1. Uncrating
2. Assembly
3. Preparation
The selling dealer assumes sole responsibility for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.

© 2016 Kawasaki Heavy Industries, Ltd.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.

NOTICE
NOTICE is used to address practices not
related to personal injury.

NOTE

○NOTE indicates information that may help or
guide you in the operation or service of the
vehicle.

Kawasaki Heavy Industries, Ltd. accepts no
liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without notice.

Feb., 2016

Table of Contents
Uncrating ......................................................................................
Opening Crate .............................................................................
Parts Check .................................................................................
Assembly ......................................................................................
Handlebars ..................................................................................
Throttle Grip and Right Switch Housing ......................................
Front Brake Master Cylinder .......................................................
Left Switch Housing.....................................................................
Clutch Cable................................................................................
Wiring Clamps .............................................................................
Lower Fairing...............................................................................
Rear View Mirrors (Left and Right) ..............................................
French Labels (For Canada Model) ............................................
Brake Disc Cleaning ....................................................................
Preparation ...................................................................................
Battery Service ............................................................................
Front Brake..................................................................................
Rear Brake ..................................................................................
Clutch Lever and Cable ...............................................................
Drive Chain..................................................................................
Rear Shock Absorber ..................................................................
Tire Air Pressures........................................................................
Fuel .............................................................................................
Engine Oil (4-stroke) ...................................................................
Throttle Grip and Cable ...............................................................
Rear Brake Light Switch ..............................................................
Headlight Aim ..............................................................................
Digital Meter ................................................................................
Fastener Check ...........................................................................
Standard Torque Table ................................................................
Test Ride the Motorcycle .............................................................
A & P Check List .........................................................................

3
3
4
6
6
6
7
7
8
8
8
11
11
12
12
12
16
18
20
21
22
23
23
23
24
25
26
27
28
30
30
30

UNCRATING 3

Uncrating
Opening Crate
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrating to prevent injury.

WARNING
The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection
when uncrating to prevent injury.

remove the lower bolts (D = 8, L = 16)
• First,
at the steering stem and discard them.
the upper bolts (D = 8, L = 16) to take
• Remove
off the crate bracket and discard them.
the lower bolts (D = 6, L = 12) to take
• Remove
off the front master cylinder.
the upper bolt (D = 8, L = 16) to take
• Remove
off the crate bracket and discard it.

A. Lower Bolts (D = 8, L = 16)
B. Upper Bolts (D = 8, L = 16)
C. Crate Bracket
D. Lower Bolts (D = 6, L = 12)
E. Washer
F. Front Master Cylinder
G. Upper Bolt (D = 8, L = 16)
H. Crate Bracket
out all the bolts and screws and remove
• Take
the top and sides of the crate.

○Roll

NOTE

the vehicle off the crate base after installing the handlebar, front master cylinder,
and front wheel.

NOTICE

a space about 6 m (20 ft) square to give
• Clear
yourself plenty of space to work.
the crate upright on its base.
• Place
the cardboard cover.
• Remove
Remove
the parts box.
•

NOTICE

When removing the crate bracket from
the motorcycle, be careful not to drop
any parts or the bracket onto the fuel
tank and other components, and not to
scratch the fuel tank or other components with the crate bracket.

When rolling the vehicle off the crate
base, sharp edges on the crate can cut
or damage tires.
Cover sharp edges with waste cloth for
tire protection as necessary.

4 UNCRATING

Parts Check

the parts box, and check the parts against the illustrations. There may be minor differences
• Open
between these illustrations and the actual vehicle parts. In the following charts under Remarks, D
= diameter in millimeters, and L = length in millimeters.

UNCRATING 5

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Part Name
Left Rear View Mirror
Right Rear View Mirror
Clamp
Handlebar Assembly
Upper Handlebar Clamp
Handlebar Clamp Bolt
Clamp, Front Brake Master Cylinder
Clamp Bolt, Front Brake Master Cylinder
Lower Fairing
Collar
Damper
Collar
Socket Bolt
Socket Bolt
Lower Faring Bracket, LH
Lower Faring Bracket Bolt
Lower Faring Bracket, RH
Battery Electrolyte, FTH4L-BS
Owner’s Manual
(French Label for Canada Model only)
French Table
Important Drive Chain Information
Tire and Load Data
Vehicle Emission Control Information

Qty
1
1
2
1
2
4
1
2
1
1
4
4
3
1
1
2
1
1
1
1
1
1
1

Remarks

L = 58

D = 8, L = 35
D = 6, L = 25
D = 6.5
D = 10
D = 6.5
D = 6, L = 20
D = 6, L = 35
D = 6, L = 10

6 ASSEMBLY

Assembly
Handlebars

the handlebars and the upper handle• Install
bar clamps so that the arrow marks on the
clamps point at the front.
Align the punch mark on the handlebars with
the mating surface at rear of the handlebar
clamp.
Tighten the handlebar clamp bolts (D = 8, L =
35) in the indicated sequence (1 to 6) to the
specified torque. There will be a gap at the
rear of the handlebar clamp after tightening.
Torque:
25 N·m (2.5 kgf·m, 18 ft·lb)

•
•

A. Throttle Grip
B. Cable Tips
C. Rear Half
D. Throttle Cable Upper Adjuster
the two halves of the right switch housing
• Fit
so that the projection on the front half fits into
the hole in the handlebars.

A. Handlebars
B. Upper Handlebar Clamps
C. Arrow Marks
D. Punched Mark
E. Handlebar Clamp Bolts (D = 8, L = 35)
F. Gaps

Throttle Grip and Right Switch
Housing
grease to the tips of the cable and con• Apply
nect it to the throttle grip.

A.
B.
C.
D.

Rear Half
Hole
Projection
Front Half

the two screws (D = 5, L = 25) and
• Insert
tighten them to the specified torque.
• Slide the dust cover.
Torque:

3.5 N·m (0.36 kgf·m, 31 in·lb)

ASSEMBLY 7

A. Right Switch Housing
B. Screws (D = 5, L = 25)
C. Dust Cover

Front Brake Master Cylinder

the right switch housing lead con• Connect
nectors to the front brake light switch termi-

A.
B.
C.
D.

Front Master Cylinder
Clamp
Punched Mark
Clamp Bolts (D = 6, L = 25)

the upper clamp bolt first and then the
• Tighten
lower clamp bolt to the specified torque.
Torque:

8.8 N·m (0.90 kgf·m, 78 in·lb)

nals on the front brake master cylinder.

Left Switch Housing

the two halves of the left switch housing
• Fit
together so that the small projection on the
front half fits into the hole in the handlebars.

A. Front Master Cylinder
B. Brake Light Switch Terminals
C. Connectors and Dust Covers
the front master cylinder with its clamp
• Install
and the two bolts (D = 6, L = 25).
the master cylinder so that the mat• Position
ing surface of the front and rear master cylinder clamps align with the punched mark on
the handlebars.

A.
B.
C.
D.

Rear Half
Hole
Projection
Front Half

the two screws (D = 5, L = 25) and
• Insert
tighten them to the specified torque.
Torque:

3.5 N·m (0.36 kgf·m, 31 in·lb)

8 ASSEMBLY

A. Left Switch Housing
B. Screws (D = 5, L = 25)
the left switch housing connector to
• Connect
the starter lockout switch on the clutch lever
assembly.

A. Clutch Cable
B. Adjuster
C. Locknut
D. Cable Tip
E. Clutch Lever

Wiring Clamps

the left and right switch harness to the
• Fasten
handlebars with clamps (L = 58).

A. Clutch Lever Assy
B. Starter Lockout Switch
C. Connector

Clutch Cable

grease to the clutch inner cable.
• Apply
Line
up
the slots on the clutch lever, locknut,
• and adjuster.
the tip of the clutch inner cable into the
• Fit
lever socket, slide the inner cable through the
slots, and release the outer cable into the adjuster.

A. Handlebars
B. Clamps (L = 58)
C. Right Switch Housing Harness
D. Left Switch Housing Harness

Lower Fairing

the right side lower fairing bracket and
• Install
bolt (D = 6, L = 10).
• Fit the projection into a hole in the bracket.

ASSEMBLY 9

A. Right Lower Fairing Bracket
B. Lower Fairing Bracket Bolt (D = 6, L =
10)
C. Projection
the left side lower fairing bracket and
• Install
bolt (D = 6, L = 10).

A. Left Lower Fairing Bracket
B. Lower Fairing Bracket Bolt (D = 6, L =
10)

• Check that the hoses are routed correctly.

10 ASSEMBLY

A. Fuel Tank Drain Hose
B. Fuel Tank Breather Hose
C. Clamp
D. Air Cleaner Housing Breather Hose
E. Face the knob of the clamp inward.
F. Clamp
G. Front
H. California Model only
the collars (D = 6.5) and dampers (D =
• Install
10) in place on the lower fairing.

A. Collars (D = 6.5)
B. Dampers (D = 6.5)
the lower fairing with socket bolts (D =
• Install
5, L = 25) (3), (D = 5, L = 35) (1) and collar (D
= 6.5).

ASSEMBLY 11

A.
B.
C.
D.

Rubber Boot
Nut (Lower)
Locknut (Upper)
Stay