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KAWASAKI KX125 KX250 Full Service & Repair Manual 1999-2002

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This manual covers the motocross motorcycles produced between 1999 and 2002. These highly capable machines represent a significant era in motocross heritage, known for their potent two-stroke engines, advanced suspension,...
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Art.-Nr: 150829
KAWASAKI KX125 KX250 Full Service & Repair Manual 1999-2002
This manual covers the motocross motorcycles produced between 1999 and 2002. These highly capable machines represent a significant era in motocross heritage, known for their potent two-stroke engines, advanced suspension, and competitive performance. Built with a focus on agility and power delivery, the KX series has a strong legacy in both amateur and professional racing circuits, reflecting a commitment to off-road excellence. The robust engineering and continuous development of these models ensure a thrilling and reliable riding experience for enthusiasts. This comprehensive Factory Service & Repair Workshop Manual provides in-depth guidance for owners, mechanics, and technicians. It details a full range of maintenance procedures, from routine tasks like oil changes and filter replacements to more complex repairs such as engine rebuilds and transmission overhauls. The manual covers all essential systems, including the engine, drivetrain, chassis, and electrical components, offering step-by-step troubleshooting and diagnostic information. With its detailed technical specifications, torque values, and clear diagrams, this resource is indispensable for maintaining the performance and longevity of your KX125 or KX250.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX125, KX250
Year:
1999, 2000, 2001, 2002
Codes
Vehicle Platform Code Kx125:
KX125 (specific chassis codes vary by sub-model year)
Vehicle Platform Code Kx250:
KX250 (specific chassis codes vary by sub-model year)
👋 Introduction
Market Position
Target Audience:
Kawasaki KX125 and KX250 owners, mechanics, performance tuners, and restoration enthusiasts
Competitive Analysis
Manual Value Proposition:
Offers complete factory-level repair and maintenance information, eliminating the need for multiple aftermarket sources and ensuring accuracy. 'No extra fees, No expiry dates' implies lifetime access to a complete resource.
Key Features
Manual Accessibility:
Instant download to various digital devices (computer, tablet, smartphone) for immediate use in the workshop or on the go.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Full service, repair, maintenance, troubleshooting, diagnostics, and specifications
Page Count
Estimated Page Count:
Comprehensive (specific page count not provided in product info, typical for full service manuals)
Manual Type
Manual Type:
Factory Service & Repair Workshop Manual
Language
Language:
English (assumed for factory manuals in this market)
Format
Digital Format:
Instant Download (PDF or similar digital format)
📖 Manual Coverage
Systems Covered
Engine Systems:
Top end (cylinder, piston, rings, head), bottom end (crankshaft, connecting rod, bearings), lubrication, cooling, ignition, carburetor, exhaust
Drivetrain Systems:
Clutch, transmission (gearbox), primary drive, final drive (chain and sprockets)
Chassis Systems:
Frame, suspension (front forks, rear shock), steering, wheels, tires, brakes (front and rear), electrical system, bodywork
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, chain adjustment and lubrication, air filter cleaning, brake fluid flush, coolant checks and changes, valve adjustments (if applicable to specific models)
Repair Procedures:
Engine rebuilds (top and bottom end), transmission overhaul, carburetor tuning and rebuilding, suspension overhaul, brake system repair, electrical component troubleshooting and replacement, frame inspection and repair
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common problems, fault finding charts, electrical schematics interpretation
Technical Depth
Technical Depth Level:
Comprehensive (from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications and tolerances)
📊 Manual Specifications
File Format
Digital File Quality:
High resolution, searchable text, printable pages (typical for professional digital manuals)
Print Quality
Print Quality Digital:
Designed for clear viewing and printing of diagrams, schematics, and text
Binding Type
Binding Type Physical Equivalent:
N/A (digital format), but equivalent to a professionally bound workshop manual
Paper Type
Paper Type Physical Equivalent:
N/A (digital format), but equivalent to high-quality, durable paper for workshop use
⚙️ Engine Specifications
Primary Engine Kx125
Engine Type Kx125:
2-stroke, liquid-cooled, single-cylinder
Bore Stroke Kx125:
Refer to manual for specific bore/stroke for 1999-2002 models (typically around 54.0 mm x 54.5 mm for this era KX125)
Displacement Kx125:
124 cc (cubic centimeters)
Primary Engine Kx250
Engine Type Kx250:
2-stroke, liquid-cooled, single-cylinder
Bore Stroke Kx250:
Refer to manual for specific bore/stroke for 1999-2002 models (typically around 66.4 mm x 72.0 mm for this era KX250)
Displacement Kx250:
249 cc (cubic centimeters)
Performance
Horsepower Output Kx125:
Refer to manual for specific output (typically 30-35 HP for this era KX125)
Horsepower Output Kx250:
Refer to manual for specific output (typically 40-45 HP for this era KX250)
Fuel System
Fuel Delivery System:
Carburetor (specific model and jetting details in manual)
Carburetor Size Kx125:
Refer to manual (typically 35mm Keihin PJ for KX125)
Carburetor Size Kx250:
Refer to manual (typically 38mm Keihin PWK for KX250)
Fuel Type Recommendation:
Unleaded gasoline (refer to manual for octane rating requirement, typically 91 octane or higher)
Two Stroke Oil Mix:
Pre-mix (refer to manual for specific ratio and recommended oil type/grade)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed manual transmission
Optional
Transmission Options:
N/A (standard configuration)
Features
Clutch Type:
Wet, multi-plate, cable-actuated
Gear Ratios:
Refer to manual for specific gear ratios for each gear and model year
Final Drive Type:
Chain drive
Transmission Oil Type:
Refer to manual for specific API GL-4 or GL-5 gear oil specification and capacity (typically SAE 80W-90)
📐 Dimensions
Exterior
Overall Length:
Refer to manual for exact dimensions (typical for 125/250 MX bikes)
Overall Width:
Refer to manual for exact dimensions
Overall Height:
Refer to manual for exact dimensions
Wheelbase:
Refer to manual for specific wheelbase (typically around 1440-1450 mm)
Ground Clearance:
Refer to manual for specific ground clearance
Weights
Dry Weight Kx125:
Refer to manual for exact dry weight (typically around 92-94 kg)
Dry Weight Kx250:
Refer to manual for exact dry weight (typically around 98-100 kg)
Wet Weight Kx125:
Refer to manual for exact wet weight (typically around 97-99 kg)
Wet Weight Kx250:
Refer to manual for exact wet weight (typically around 103-105 kg)
Fuel Tank Capacity:
Refer to manual for exact capacity (typically 8.0 liters / 2.1 US gallons)
🛡️ Safety Features
Ratings
Safety Certification:
N/A (Off-road motorcycle, not typically subject to road safety certifications like NCAP)
Active Features
Braking System Front:
Hydraulic disc brake (refer to manual for caliper and rotor specifications)
Braking System Rear:
Hydraulic disc brake (refer to manual for caliper and rotor specifications)
Suspension Features:
Long-travel, adjustable front forks and rear shock absorber for off-road performance and impact absorption.
Passive Features
Frame Construction:
High-tensile steel perimeter frame designed for rigidity and impact resistance.
💡 Technology Features
Infotainment
Infotainment System:
N/A (purpose-built motocross motorcycles, no infotainment features)
Driver Assistance
Driver Assistance Features:
N/A (off-road motorcycle)
Connectivity
Connectivity Features:
N/A (off-road motorcycle)
Engine Technology
Power Valve System:
Kawasaki Integrated Power Valve System (KIPS) or similar system for optimizing power delivery across the RPM range.
Ignition System:
Digital CDI (Capacitor Discharge Ignition) for precise spark timing.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Refer to manual for specific recommendations based on usage (e.g., every 5-10 hours of riding for performance-oriented use)
Air Filter Cleaning Interval:
Refer to manual (critical for 2-stroke engines; often recommended after every few rides or when visibly dirty)
Spark Plug Replacement:
Refer to manual for recommendations (typically inspected and cleaned regularly, replaced as needed based on condition)
Chain Lubrication Adjustment:
Refer to manual (critical for longevity; typically checked and adjusted every few rides)
Fluid Specifications
Coolant Type:
Refer to manual for specific coolant type (typically ethylene glycol-based antifreeze, 50/50 mix with distilled water)
Brake Fluid Type:
Refer to manual for specific brake fluid specification (typically DOT 4)
Two Stroke Oil Recommendation:
Refer to manual for specific API TC, JASO FD, or ISO-L-EGD rated 2-stroke oil
Known Issues
Common Kx Issues Era:
Clutch wear, carburetor jetting sensitivity to altitude/temperature, piston ring wear, power valve operation (cleaning/adjustment), suspension seal leaks, chain/sprocket wear.
Technical Specs Engine
Piston Ring Gap Spec:
Refer to manual for precise piston ring end gap specifications for both models.
Cylinder Bore Tolerance:
Refer to manual for cylinder bore finish and out-of-round tolerances.
Crankshaft Runout Spec:
Refer to manual for maximum crankshaft runout specification.
📚 Vehicle History
Brand Heritage
Kawasaki Motocross Legacy:
Kawasaki has a long and successful history in professional motocross racing, with the KX line being a cornerstone of their off-road performance.
Model Evolution
Kx Series Evolution:
The KX125 and KX250 models underwent continuous development through the late 1990s and early 2000s, with incremental improvements in suspension, engine power delivery, chassis handling, and braking systems.
Production
Manufacturing Location:
Japan (primary manufacturing location for Kawasaki motorcycles)
Production Period:
1999-2002 models represent a specific generation of these highly competitive motocross machines.
🏆 Awards & Recognition
Recognitions
Model Racing Success:
The KX125 and KX250 platforms have historically been successful in amateur and professional motocross and supercross racing, contributing to their market appeal.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for performance and durability when properly maintained. Detailed ratings are subjective and not typically published for specific model years of off-road bikes.
Certifications
Manufacturer Certification:
Factory produced by Kawasaki Heavy Industries, adhering to their internal quality and performance standards.
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