Segment:
Professional Motocross (MX) Competition
Target Audience:
Motocross Enthusiasts, Mechanics, Race Teams, Owners Requiring In-depth Maintenance and Repair Knowledge
Manual Value:
Provides comprehensive factory-level information, essential for maintaining peak performance and longevity of these high-performance competition machines. Rivals dealer-level service capabilities.
Completeness:
Factory authorized procedures, diagrams, and specifications for all service and repair aspects.
Accessibility:
Immediate availability via digital download, offering convenience and a cost-effective solution compared to physical manuals.
Licensing:
Perpetual license, no recurring fees or subscriptions.
Primary Coverage:
Complete Service, Repair, and Workshop Procedures
Diagnostic Coverage:
Troubleshooting Guides, Fault Diagnosis
Maintenance Coverage:
Routine Maintenance, Scheduled Service
Disassembly Assembly Coverage:
Complete Component Disassembly and Reassembly
Technical Data Coverage:
Specifications, Torque Values, Clearances
Estimated Page Count:
1000+
Type:
Factory Service Manual / Workshop Manual / Repair Manual
Format:
Digital Download (PDF)
Accessibility:
Instant Download for Computer, Tablet, Smartphone
Engine:
Top End (Cylinder, Piston, Rings), Bottom End (Crankshaft, Connecting Rod, Bearings), Carburetion, Cooling System (if applicable), Lubrication System, Ignition System, Exhaust System
Transmission:
Clutch (Wet Multi-plate), Gearbox (5-Speed), Shift Mechanism, Internal Components
Chassis:
Frame, Swingarm, Suspension (Front Fork - USD, Rear Shock Absorber), Steering System, Front and Rear Wheels, Tires, Brakes (Front and Rear Disc Brakes), Handlebars, Footpegs
Electrical:
Ignition System (CDI), Lighting System (if applicable, though typically minimal on competition MX bikes), Wiring Harness, Charging System (if applicable)
Bodywork:
Plastic Panels (Fenders, Shrouds), Seat, Fuel Tank, Graphics
General Maintenance:
Oil Changes, Filter Replacements (Air, Oil), Chain Adjustment and Lubrication, Spark Plug Service, Brake Pad Inspection and Replacement, Coolant Flush and Refill (if applicable)
Engine Rebuild:
Top End Rebuild (Piston, Rings, Cylinder Honing), Bottom End Rebuild (Crankshaft Seal Replacement, Bearing Replacement), Valve Adjustment (if applicable, though typically two-stroke), Carburetor Cleaning and Adjustment
Transmission Service:
Clutch Service (Friction Plate Replacement, Spring Replacement), Gearbox Oil Change, Inspection of Gears and Dog Teeth
Suspension Service:
Fork Seal Replacement, Fork Oil Change and Level Adjustment, Rear Shock Absorber Service (Oil and Gas Seals)
Brake System Service:
Brake Pad Replacement, Rotor Inspection, Brake Fluid Flush and Bleed, Caliper Service
Troubleshooting:
Diagnostic Charts for Performance Issues, Starting Problems, Engine Noise, Electrical Faults
Depth:
Comprehensive: Covers basic maintenance, routine servicing, advanced diagnostics, complete engine and transmission rebuilds, suspension overhaul, and chassis component repair.
Diagnostic Capability:
Detailed troubleshooting flowcharts and symptom-based diagnostics.
Rebuild Complexity:
Suitable for complete engine disassembly, inspection, and reassembly, including crankshaft and gearbox components.
Engine Type Kx125:
Liquid-Cooled, 2-Stroke, Reed Valve, Single Cylinder
Displacement Kx125:
124 cc (7.57 cu in)
Bore X Stroke Kx125:
54.0 x 54.5 mm (2.13 x 2.15 in)
Engine Type Kx250:
Liquid-Cooled, 2-Stroke, Reed Valve, Single Cylinder
Displacement Kx250:
249 cc (15.19 cu in)
Bore X Stroke Kx250:
66.4 x 72.0 mm (2.61 x 2.83 in)
Compression Ratio Kx125:
9.8:1 (Typical, subject to variation)
Compression Ratio Kx250:
8.9:1 (Typical, subject to variation)
Carburetor Kx125:
Keihin PWK37 (or similar 37mm flat-slide carburetor)
Carburetor Kx250:
Keihin PWK38 (or similar 38mm flat-slide carburetor)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Mixture Ratio:
50:1 (Kawasaki KDX 2-stroke oil recommended, but manual will specify precise type and ratio)
Engine Oil Change:
Every 10-15 hours of riding, or as per manual's recommendation based on riding conditions.
Air Filter Cleaning:
After every riding session, or more frequently in dusty conditions.
Spark Plug Service:
Inspect every 10-15 hours, replace as needed. Manual will provide specific part numbers and gap settings.
Chain Lubrication Adjustment:
Before every ride, or every 5-10 hours. Check for proper tension.
Top End Rebuild Interval:
Highly variable based on usage and maintenance, but typically recommended between 40-100 hours for competitive use. Manual will detail inspection points.
Engine Oil Type:
High-quality 2-stroke racing oil (Specific recommendations in manual)
Transmission Oil Capacity:
Approx. 0.65 L (0.69 US qt) for KX125, 0.75 L (0.79 US qt) for KX250 (refer to manual for exact capacity)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid (Manual will specify)
Coolant Type:
Mixture of distilled water and motorcycle-specific antifreeze/coolant (50/50 ratio typical, refer to manual)
Typical Wear Items:
Piston rings, clutch plates, spark plugs, air filters, chain and sprockets, brake pads, fork seals.
Engine Considerations:
2-stroke engines require diligent adherence to fuel/oil mixture, timely top-end rebuilds, and proper carburation to prevent issues like plug fouling or pre-ignition.
Suspension Maintenance:
Regular fork seal and oil maintenance is critical for optimal suspension performance and longevity.
Heritage:
Kawasaki has a long and successful history in motocross racing, with the KX line being a dominant force for decades. Known for innovation and performance-oriented designs.
Kx Line Evolution:
The KX125 and KX250 models represent the evolution of Kawasaki's 2-stroke motocross technology leading up to the mid-2000s. Key developments include chassis improvements, suspension advancements, and engine tuning for increased power and responsiveness.
2003-2007 Era:
This generation of KX models saw significant updates, including revised suspension settings, improved engine character, and chassis refinements aimed at enhancing handling and rider feedback. The KX250 notably underwent a major redesign in 2005.
Manufacturing Origin:
Japan (Primary manufacturing location for Kawasaki Motorcycles)
