Kawasaki KX125/KX250 Service Manual Repair 1992-1993 KX 125 250

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Art.-Nr: 151438

Stichworte: 1992 1993 Kawasaki KX 125 KX 250 KX Series KX125 KX250 Motorcycle Motorcycles

Produktvarianten

Beschreibung

This manual covers the KX125 and KX250 models produced in 1992 and 1993. These performance off-road motorcycles are renowned for their potent two-stroke engines, agile handling, and significant contributions to motocross racing heritage. Engineered for competitive riding, these models feature advanced technologies such as the Integrated Power Valve System (KIPS) to optimize power delivery across the RPM range. They were built with a focus on delivering aggressive performance and are recognized for their durability and competitive edge in their segment. This comprehensive Factory Service Manual provides detailed information essential for the maintenance, diagnosis, and repair of your KX125 or KX250. It covers all main systems, including the engine, chassis, electrical components, bodywork, suspension, brakes, and drivetrain. Within its 236 pages, you will find step-by-step procedures for engine mechanicals, fuel and ignition systems, transmission, suspension, and brakes, along with troubleshooting guides, diagnostic procedures, and torque specifications. This English-language resource is designed to assist owners and technicians in maintaining optimal performance and ensuring the longevity of these high-performance machines.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX125/KX250

Years Covered:

1992, 1993

Codes

Model Codes Kx125:

KX125-K1, KX125-K2

Model Codes Kx250:

KX250-K1, KX250-K2

👋 Introduction

Market Position

Segment:

Performance Off-Road Motorcycles (Motocross)

Competitors:

Honda CR125R/CR250R, Yamaha YZ125/YZ250, Suzuki RM125/RM250, KTM 125 EXC/250 EXC (early models).

Key Features

Model Characteristics:

Known for potent two-stroke power delivery, agile handling, and competitive performance in motocross racing. These models were a significant part of Kawasaki's off-road racing heritage.

Manual Utility:

Essential resource for owners and mechanics to maintain, diagnose, and repair these performance-oriented machines, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Main Systems:

Engine, Chassis, Electrical, Bodywork, Suspension, Brakes, Drivetrain

Specific Components:

Carburetor, Ignition System, Exhaust System, Cooling System (Radiator), Fuel Tank, Swingarm, Linkage, Forks, Shock Absorber, Wheels, Tires, Clutch, Transmission, Kick Starter, Shift Lever, Brake Rotors and Calipers, Handlebars, Seats, Fenders, Plastics

Page Count

Total Pages:

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine tear down and rebuild, piston, connecting rod, crankshaft, cylinder, cylinder head, valves, seals, gaskets, bearings, lubrication system, cooling system.

Fuel System:

Carburetor (Mikuni VM series), jetting, needle settings, float levels, pilot jet, main jet, mixture screw adjustments, throttle cable, intake boot.

Ignition System:

CDI ignition, stator, flywheel, spark plug, ignition timing, troubleshooting no spark.

Transmission Drivetrain:

Clutch operation and adjustment, gear shifting mechanism, transmission gears, primary reduction gear, output shaft, chain drive, sprockets.

Suspension Steering:

Front fork (telescopic) disassembly, assembly, oil levels, spring rates, damping adjustments, rear shock absorber service, linkage maintenance, steering stem bearings.

Brakes:

Hydraulic disc brake systems (front and rear), caliper service, master cylinder rebuild, brake fluid specifications, pad replacement, rotor inspection, bleeding procedure.

Electrical System:

Lighting (headlight, taillight), horn, CDI unit, rectifier/regulator (if applicable), wiring diagrams, troubleshooting electrical faults.

Chassis Bodywork:

Frame inspection, swingarm removal and installation, wheel bearings, steering stem, seat, fenders, plastics, graphics.

Procedures Included

Maintenance:

Regular servicing, oil changes (pre-mix or oil injection for some), filter cleaning/replacement, chain adjustment, general lubrication, tightening checks.

Repair Rebuild:

Complete engine overhaul, transmission rebuild, suspension component repair, brake system overhaul, carburetor rebuild.

Troubleshooting:

Diagnostic procedures for common problems, no-start conditions, poor running, overheating, electrical issues, clutch slip, suspension leaks.

Diagnostics:

Systematic fault finding based on symptoms, including engine performance, ignition, and fuel delivery issues.

Installation:

Instructions for component replacement, such as exhaust systems, handlebars, plastics, and brake components.

Technical Depth

Depth Level:

Comprehensive, covering all aspects from routine maintenance to full engine and chassis rebuilds, including detailed diagrams and specifications.

Visual Aids:

Includes numerous photographs, illustrations, and part diagrams to aid in identification and procedural understanding.

Data Specifications:

Provides critical technical data including torque specifications, fluid capacities, clearances, and measurement tolerances.

📊 Manual Specifications

File Format

PDF Features:

Searchable text, clickable chapters, no printing or saving restrictions.

Print Quality

Image Resolution:

High quality, suitable for printing.

Binding Type

Digital Binding:

N/A (Digital PDF)

Paper Type

Digital Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine Kx125

Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

124 cc (approx.)

Bore X Stroke:

56.0 x 49.2 mm (approx.)

Compression Ratio:

9.0:1 (approx.)

Primary Engine Kx250

Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

249 cc (approx.)

Bore X Stroke:

66.4 x 72.0 mm (approx.)

Compression Ratio:

8.9:1 (approx.)

Performance

Power Delivery:

Aggressive, peaky powerband characteristic of performance 2-stroke motocross bikes of this era.

Fuel System

Carburetor Kx125:

Mikuni VM29SS

Carburetor Kx250:

Mikuni VM34SS

Fuel Type:

Unleaded gasoline (octane rating as specified in manual), mixed with 2-stroke oil (pre-mix, often 20:1 or 32:1 depending on application).

Ignition Type:

Digital CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain

📐 Dimensions

Weights

Dry Weight Kx125:

Approx. 93 kg / 205 lbs

Dry Weight Kx250:

Approx. 102 kg / 225 lbs

Fuel Tank Capacity:

8.0 liters (approx. 2.1 US gal)

Suspension Travel

Front Suspension Travel:

Approx. 280-300 mm (11.0-11.8 inches)

Rear Suspension Travel:

Approx. 290-310 mm (11.4-12.2 inches)

Wheels Tires

Front Wheel Size:

21 inches

Rear Wheel Size:

18 inches

Front Tire Size:

80/100-21 (typical)

Rear Tire Size:

100/90-18 or 110/90-18 (typical)

💡 Technology Features

Infotainment

Features:

N/A (Analog motorcycle with focus on performance and function).

Driver Assistance

Features:

N/A (No electronic rider aids typically found on modern motorcycles).

Connectivity

Features:

Performance Enhancements

Powervalve System:

Kawasaki Integrated Power Valve System (KIPS) designed to optimize power delivery across the RPM range.

🔧 Maintenance

Service Intervals

Air Filter Cleaning:

After each ride or as needed, depending on conditions.

Spark Plug Inspection:

Every 10-20 hours of operation.

Chain Lubrication Adjustment:

Lubricate every 300-500 km (180-300 miles) or as needed; adjust tension every 1000 km (600 miles).

Engine Oil Change Transmission:

Not applicable (2-stroke, pre-mix or oil injection system if equipped).

Coolant Change:

Every 12 months or as per manual recommendation.

Fluid Specifications

Engine Oil:

High-quality 2-stroke motorcycle oil (e.g., API TC, JASO FD rated). Specific viscosity recommended in manual (e.g., SAE 20W-50 for transmission oil if separate).

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid.

Fork Oil:

Specific grade and volume as detailed in manual (e.g., SAE 10W fork oil).

Known Issues

Common Wear Items:

Piston rings, spark plugs, clutch plates, chain and sprockets, wheel bearings, swingarm bushings, fork seals, carburetor jets.

Engine Performance:

Carburetor jetting sensitivity to altitude and temperature, potential for carbon buildup in exhaust port and powervalve, kickstart mechanism wear.

Suspension:

Fork seal leaks, shock absorber damping degradation over time, linkage bearing wear.

📚 Vehicle History

Brand Heritage

Kawasaki Offroad:

Kawasaki has a long and successful history in off-road motorcycle racing, particularly in motocross and enduro, with the KX line being a cornerstone of their competitive efforts.

Model Evolution

Kx Series Era:

The early 1990s were a period of intense development in motocross technology. The KX125 and KX250 models of this era featured advancements in suspension, chassis design, and engine performance to remain competitive.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Racing Success:

These models were competitive in their respective classes during their production years, contributing to Kawasaki's racing pedigree. Specific awards would be tied to individual racing events and championships.