kawasaki KX125M1 thru KX125M8F 2003 to 2008 Workshop Manual

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Stichworte: 2003 2004 2005 2006 2007 2008 Kawasaki KX Series KX125M1 KX125M2 KX125M3 KX125M4 KX125M5 KX125M6 KX125M7 KX125M8F Motorcycle Motorcycles

Produktvarianten

Beschreibung

This workshop manual covers the motocross competition motorcycle from 2003 to 2008, and the from 2003 to 2004. These models are known for their liquid-cooled, 2-stroke engines featuring the Integrated Power Valve System (KIPS), high-performance Kayaba suspension, and lightweight aluminum perimeter frames, designed for peak performance in competitive off-road racing. This comprehensive 348-page factory service manual provides detailed instructions for maintenance, repair, and troubleshooting across all major systems, including the engine, transmission, fuel, ignition, suspension, and brakes. It is an essential resource for technicians and experienced owners, offering in-depth guidance from routine servicing to complete overhauls, ensuring the optimal performance and longevity of these high-performance machines.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX125

Model Variant:

M1, M2, M3, M6F, M7F, M8F

Covered Model Variant:

KX250 (M1, M2)

Generation

Year Start:

Year End:

Codes

Kx125 Vin Prefix Examples:

JKAKXRMC, JKAKX125MMA

Kx250 Vin Prefix Examples:

JKAKXMMC, JKAKX250MMA

👋 Introduction

Market Position

Vehicle Class:

Motocross Competition Motorcycle

Target Audience:

Motocross racers, off-road enthusiasts, mechanics

Competitive Analysis

Key Competitors Era:

Yamaha YZ125, Honda CR125R, Suzuki RM125

Key Features

Engine Design:

Liquid-cooled, 2-stroke, single-cylinder with Kawasaki Integrated Power Valve System (KIPS)

Suspension Tech:

High-performance Kayaba components, adjustable front and rear

Chassis Design:

Lightweight aluminum perimeter frame

📋 Manual Details

Coverage Areas

Primary Focus:

Kawasaki KX125 (2003-2008)

Secondary Focus:

Kawasaki KX250 (2003-2004)

Page Count

Total Pages:

Manual Type

Type:

Workshop Manual / Service Manual

Source:

Factory Manual

Manual Purpose:

Repair and maintenance guide for technicians and experienced owners

Language

Language:

English

Format

Format:

Physical Book (Assumed)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine assembly, disassembly, inspection, and repair

Transmission:

Gearbox, clutch, shifting mechanisms

Cooling System:

Radiator, hoses, water pump

Fuel System:

Carburetor (Keihin PWK), fuel lines, fuel tank

Ignition System:

CDI unit, spark plug, stator, ignition timing

Exhaust System:

Exhaust pipe, silencer, power valve system

Suspension:

Front forks (Kayaba USD), rear shock absorber (Kayaba), linkages

Brakes:

Front and rear disc brake systems, hydraulic components

Wheels And Tires:

Wheel bearing service, tire installation and removal

Electrical System:

Wiring diagrams, lighting, kill switch

Frame And Bodywork:

Chassis components, plastic body panels, seat

Procedures Included

Maintenance:

Regular service, oil changes, filter replacements, chain adjustment

Troubleshooting:

Diagnostic flowcharts and problem-solving guides for common issues

Repair:

Detailed step-by-step repair instructions for all major components

Disassembly Assembly:

Complete guide for engine, transmission, and chassis components

Adjustments:

Carburetor tuning, clutch adjustment, suspension setup

Torque Specifications:

Essential torque values for critical fasteners

Technical Depth

Depth:

Comprehensive, from basic maintenance to full engine rebuilds and chassis overhauls

Diagnostic Capability:

Advanced diagnostic procedures and troubleshooting for all systems

📊 Manual Specifications

File Format

Digital Format:

Not specified (assumed printed)

Print Quality

Quality:

Professional factory printing (implied by 'Factory manual')

Binding Type

Binding:

Perfect Bound or Saddle-Stitched (typical for workshop manuals)

Paper Type

Paper:

Durable, semi-gloss paper suitable for workshop environments

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled, single-cylinder

Displacement:

124 cc (for KX125), 249 cc (for KX250)

Bore X Stroke Kx125:

54.0 x 54.5 mm (typical for this generation KX125)

Bore X Stroke Kx250:

66.4 x 72.0 mm (typical for this generation KX250)

Compression Ratio Kx125:

8.7:1 (typical for this generation KX125)

Valvetrain:

KIPS (Kawasaki Integrated Power Valve System)

Performance

Horsepower Kx125:

Approx. 35-40 HP (at crankshaft, varies by year/tune)

Torque Kx125:

Approx. 17-19 lb-ft (at crankshaft, varies by year/tune)

Fuel System

Carburetor:

Keihin PWK38S (for KX125), Keihin PWK39S (for KX250)

Fuel Type:

Unleaded gasoline with 2-stroke oil mix (premix required)

Fuel Mix Ratio:

Typically 32:1 or 40:1 (refer to manual for specific recommendation)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch:

Wet multi-disc, cable-actuated

Features

Gear Ratios:

Specific ratios provided in manual

Final Drive:

Chain drive (e.g., 13T front, 50T rear)

Transmission Oil Type:

SAE 80 or SAE 10W-30 API GL-4 hypoid gear oil (refer to manual for exact specification)

📐 Dimensions

Exterior

Length:

Approx. 2170 mm (for KX125)

Width:

Approx. 815 mm (for KX125)

Height:

Approx. 1255 mm (for KX125)

Wheelbase:

Approx. 1475 mm (for KX125)

Weights

Dry Weight Kx125:

Approx. 92 kg (202.7 lbs)

Fuel Tank Capacity:

8.0 Liters (2.1 US gal)

Seat Height:

Approx. 950 mm (for KX125)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable (competition off-road vehicle)

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power

Passive Features

Frame Construction:

Rigid perimeter frame for chassis integrity and rider confidence

💡 Technology Features

Infotainment

Infotainment System:

None (focus on pure performance)

Driver Assistance

Assistance Features:

None (focus on rider input and control)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Refer to manual for specific intervals based on usage (e.g., every 10-15 hours of riding)

Air Filter Cleaning:

Recommended after every few rides or as per manual's guidance

Spark Plug Replacement:

Refer to manual, typically every 20-30 hours of riding

Chain Lubrication Adjustment:

Regularly, before and after each riding session

Fluid Specifications

Coolant Type:

Permanent antifreeze coolant (e.g., 50/50 mix of ethylene glycol and distilled water)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Known Issues

Power Valve Sticking:

Can occur due to carbon buildup; requires regular cleaning as per manual instructions.

Clutch Wear:

Standard wear item for a competition bike; clutch plates may need replacement based on usage.

Suspension Seals:

Fork seals and shock seals can wear over time, requiring replacement to maintain performance.

Carburetor Jetting:

May require adjustments based on altitude, temperature, and modifications for optimal performance.

📚 Vehicle History

Brand Heritage

Kawasaki Motocross:

Kawasaki has a long and successful history in professional motocross racing, with the KX line being a cornerstone of their off-road performance division.

Model Evolution

Kx125 Evolution Era:

This generation of the KX125 (M-series) represented Kawasaki's efforts to maintain competitiveness in the highly contested 125cc class with advancements in engine technology and chassis design.

Production

Production Period:

2003-2008 for KX125, 2003-2004 for KX250 within this manual's scope.

🏆 Awards & Recognition

Recognitions

Motocross Performance:

While specific awards for these exact model years are not readily cited, the KX125 line historically received accolades for its performance and race-winning capabilities.