2003-2005 Kawasaki KX125 KX250 2Stroke Motorcycle Repair

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Art.-Nr: 145282

Stichworte: 2003 2004 2005 Kawasaki KX Series KX125 KX250 Motorcycle Motorcycles

Produktvarianten

Beschreibung

This manual covers the dirt bikes produced between 2003 and 2005. These 2-stroke motocross motorcycles are renowned for their aggressive power delivery, lightweight chassis, and long-travel suspension, making them formidable machines for competitive off-road riding. The extensive history in motocross racing underpins the performance and engineering of these models, which have consistently been praised for their handling and engine capabilities. This documentation aims to provide comprehensive support for owners and technicians working with these high-performance off-road vehicles. The scope of this service manual is extensive, encompassing all essential aspects of repair, maintenance, and troubleshooting for the specified models. It includes detailed procedures for engine disassembly, assembly, and tuning, covering critical systems such as the fuel, lubrication, and transmission. Furthermore, the manual provides guidance on suspension service, steering system maintenance, electrical system diagnostics, and bodywork procedures. With its in-depth technical information, including torque specifications, component identification, and troubleshooting charts, this manual serves as an indispensable resource for maintaining the optimal performance and longevity of your 125 or 250.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Model Years Covered:

2003, 2004, 2005

Codes

Vehicle Type:

Dirt Bike / Motocross Motorcycle

Engine Type:

2-Stroke

👋 Introduction

Market Position

Market Segment:

Performance Motocross/Off-Road Motorcycles

Competitive Analysis

Key Competitors:

Yamaha YZ125/YZ250, Honda CR125R/CR250R, KTM 125/250 SX

Key Features

Vehicle Focus:

Aggressive power delivery, lightweight chassis, long-travel suspension for competitive motocross and off-road riding.

Manual Benefits

Digital Advantage:

Instant access, easy to use on mobile devices for on-trail repairs, avoids damage to physical manuals.

Lifetime Protection Policy:

Free replacement of the digital manual if lost or damaged.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, Service, Maintenance, Troubleshooting

Secondary Coverage:

Parts lookup, Component identification

Manual Types Available:

Repair Manual, Owner's Manuals, Parts Catalogs (as mentioned in the product description, though this specific product focuses on repair/service).

Page Count

Estimated Page Count:

Refer to specific manual (typical for this era ~400-600 pages per model)

Manual Type

Manual Type:

Service Manual / Workshop Manual

Content Scope:

Contains all information needed to perform repairs, look up parts, or do routine maintenance.

Language

Language:

English

Format

Format:

Downloadable PDF

Download Method:

Instant download after payment, no zip files or additional software required.

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine disassembly, assembly, tuning, and repair for both KX125 and KX250 2-stroke engines.

Fuel System:

Carburetor identification, adjustment, overhaul, and troubleshooting; fuel tank, petcock, and fuel line service.

Lubrication And Cooling:

2-stroke oil injection system (if applicable), gearbox oil specification and change intervals, cooling system inspection (if liquid-cooled).

Transmission Drive Chain Sprockets:

Clutch operation, inspection, and replacement; gearbox disassembly and assembly; drive chain adjustment and replacement; sprocket inspection and replacement.

Steering System:

Handlebar and clamp inspection; steering stem bearing service, adjustment, and replacement.

Suspension Shocks:

Front fork (telescopic) disassembly, seal replacement, oil type and level specifications, adjustment procedures. Rear shock absorber inspection, linkage maintenance, and rebuild procedures.

Body Work:

Plastic body panel removal and installation, seat maintenance, fender replacement, graphics application.

Intake Exhaust:

Airbox and filter service; exhaust pipe and silencer inspection, removal, and installation.

Electrical System:

Ignition system components, wiring diagrams, lighting (if applicable), battery maintenance, troubleshooting electrical faults.

Engine Specifications:

Detailed specifications for engine components, torque values, clearances, and assembly procedures.

Procedures Included

Routine Maintenance:

Pre-ride inspections, cleaning, chain lubrication, air filter cleaning/replacement, oil changes (gearbox), spark plug checks.

Engine Overhaul:

Top-end rebuild (piston, rings, cylinder, cylinder head), bottom-end service (crankshaft, bearings, seals), power valve service and adjustment.

Troubleshooting:

Diagnostic charts for common problems such as starting issues, poor running, overheating, and electrical faults.

Component Replacement:

Detailed step-by-step guides for replacing all major and minor components of the motorcycle.

Engine Removal Installation:

Comprehensive steps for safely removing and reinstalling the engine from the motorcycle frame.

Technical Depth

Depth Of Coverage:

Comprehensive, suitable for both amateur mechanics and professional technicians; covers everything from basic adjustments to full engine rebuilds.

Troubleshooting Level:

Advanced troubleshooting guides and diagnostic procedures for identifying and resolving complex issues.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality Recommendation:

Printable on standard office printers; high-resolution for clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type Recommendation:

N/A (Digital Download - recommended for printing on durable paper)

⚙️ Engine Specifications

Primary Engine

Kx125 Engine Type:

Liquid-cooled, 2-stroke, single cylinder, Reed Valve

Kx250 Engine Type:

Liquid-cooled, 2-stroke, single cylinder, Reed Valve

Performance

Kx125 Bore X Stroke:

54.0 x 54.5 mm (typical for this generation)

Kx125 Displacement:

124 cc

Kx250 Bore X Stroke:

66.4 x 72.0 mm (typical for this generation)

Kx250 Displacement:

249 cc

Power Delivery:

Known for strong mid-range to top-end power characteristics.

Fuel System

Carburetor Kx125:

Keihin PWK36 (typical)

Carburetor Kx250:

Keihin PWK38 (typical)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

2 Stroke Oil Mixture:

Pre-mix or automatic injection system (refer to manual for specific grade and ratio if pre-mix).

🔧 Transmission

Standard

Kx125 Transmission:

6-speed constant mesh

Kx250 Transmission:

6-speed constant mesh

Features

Clutch Type:

Wet multi-disc

Final Drive:

Chain drive

Gearbox Oil Type:

API GL-4, SAE 80W/90 hypoid gear oil (refer to manual for specific capacity and part number)

📐 Dimensions

Exterior

Frame Type:

Perimeter cradle, high-tensile steel (typical)

Weights

Dry Weight Kx125:

Approx. 93 kg / 205 lbs

Dry Weight Kx250:

Approx. 100 kg / 220 lbs

🛡️ Safety Features

Ratings

Safety Features:

Standard motorcycle safety features; emphasis on rider skill and control.

Active Features

Brakes:

Front: Hydraulic disc brake. Rear: Hydraulic disc brake.

Passive Features

Suspension:

Long-travel, adjustable suspension for absorbing impacts and maintaining control.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Dedicated performance off-road motorcycle, no infotainment systems).

Driver Assistance

Assistance Features:

N/A (Focus on rider control and mechanical feedback).

🔧 Maintenance

Service Intervals

Air Filter Cleaning:

After every few rides or as needed based on conditions (highly recommended).

Gearbox Oil Change:

Every 10-15 hours of riding or annually (refer to manual for exact recommendations).

Spark Plug Check:

Regularly, especially if experiencing running issues.

Chain Lubrication Adjustment:

Every ride or every few rides, depending on conditions.

Fluid Specifications

Front Fork Oil Type Kx125:

Kawasaki KDX 08 (or equivalent high-quality suspension fluid with appropriate viscosity, e.g., Showa SS-08, Maxima 5W)

Front Fork Oil Level Kx125:

Refer to manual for specific oil level (e.g., 120-130 mm from top of fork tube).

Front Fork Oil Type Kx250:

Kawasaki KDX 08 (or equivalent high-quality suspension fluid with appropriate viscosity, e.g., Showa SS-08, Maxima 5W)

Front Fork Oil Level Kx250:

Refer to manual for specific oil level (e.g., 120-130 mm from top of fork tube).

Known Issues

Common Kx125 Kx250 Issues:

Worn piston rings and cylinder bores due to aggressive use, clutch wear, carburetor jetting sensitivity to altitude and temperature, suspension seal leaks, power valve sticky operation.

Part Numbers

Air Filter Part Number Example:

Generic example: K&N KA-1203 (Actual part numbers require specific model lookup in a parts catalog or manual).

Gearbox Oil Capacity Kx125:

Approx. 0.7 Liters (0.74 US qt) (Refer to manual for exact capacity)

Gearbox Oil Capacity Kx250:

Approx. 0.8 Liters (0.85 US qt) (Refer to manual for exact capacity)

📚 Vehicle History

Brand Heritage

Kawasaki Offroad Legacy:

Kawasaki has a long and storied history in motocross and off-road racing, with the KX line being a dominant force for decades.

Model Evolution

Kx125 Kx250 Evolution 2003-2005:

This generation of KX models received significant updates, including chassis refinements, engine tuning, and suspension improvements aimed at enhancing performance and competitiveness in their respective classes.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motocross Class Performance:

The KX125 and KX250 lines have historically been highly competitive in their respective classes, often receiving praise for engine performance and chassis handling from motorcycle publications.