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kX125-kX250 Service serivce Manual 1999-2002

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This manual covers the KX125 and KX250 motorcycles from the 1999 to 2002 model years. These performance-oriented two-stroke machines are renowned for their competitive edge in motocross and off-road racing,...
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kX125-kX250 Service serivce Manual 1999-2002
This manual covers the KX125 and KX250 motorcycles from the 1999 to 2002 model years. These performance-oriented two-stroke machines are renowned for their competitive edge in motocross and off-road racing, building on a strong heritage in the sport. Engineered for aggressive power delivery and agile handling, the KX series of this era featured advanced technologies such as the Integrated Power Valve System (KIPS) to optimize engine performance across the RPM range. They are characterized by their robust perimeter frames, potent single-cylinder engines, and reliable suspension systems, making them a favored choice for serious riders. The purpose of this comprehensive Workshop Service Repair Manual is to provide detailed guidance for the maintenance, troubleshooting, and repair of your KX125 or KX250. It encompasses a wide array of essential information, including general specifications, periodic maintenance schedules, and in-depth procedures for all major systems. Key areas covered include the fuel, cooling, lubrication, and electrical systems, as well as the engine top end, clutch, transmission, wheels, brakes, suspension, and frame. This manual is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of these high-performance motorcycles through accurate and detailed technical instructions.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX125 / KX250
Product Name:
kX125-kX250 Service Manual 1999-2002
Product Description:
1999-2002 Kawasaki KX125-KX250 Motorcycle Workshop Service Repair Manual
Codes
Model Codes 1999:
KX125-L1, KX250-L1
Model Codes 2000:
KX125-L2, KX250-L2
Model Codes 2001:
KX125-L3, KX250-L3
Model Codes 2002:
KX125-L4, KX250-L4
Generation
Covered Years:
1999, 2000, 2001, 2002
👋 Introduction
Market Position
Positioning:
The Kawasaki KX series of the late 90s and early 2000s were highly regarded motocross and off-road racing machines, known for their potent two-stroke engines and competitive chassis. This manual is aimed at owners and technicians needing to maintain and repair these performance-oriented motorcycles.
Competitive Analysis
Competitors:
Competes directly with service manuals for Yamaha YZ series, Honda CR series, and Suzuki RM series of the same period. Known for robust engine performance and a direct, engaging riding feel.
Key Features
Manual Highlights:
Extensive coverage of the two-stroke engines, detailed wiring diagrams, and comprehensive suspension adjustment procedures specific to motocross applications.
📋 Manual Details
Coverage Areas
Major Sections:
General Information, Periodic Maintenance, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Page Count
Estimated Page Count:
Approximately 400-600 pages (typical for comprehensive service manuals of this era)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF) - Searchable and Printable
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Top End (cylinder, piston, rings, head), Clutch (operation, adjustments, components), Engine Lubrication System (oil pump, passages), Crankshaft/Transmission (gearbox, shifting mechanism, bearings), Fuel System (carburetor, fuel lines, petcock), Cooling System (radiator, hoses, coolant)
Chassis:
Wheels/Tires (rims, spokes, tire mounting, balancing), Final Drive (chain, sprockets), Brakes (hydraulic systems, pads, discs, calipers), Suspension (front forks, rear shock, linkages, adjustments), Steering (headset, handlebars, controls)
Electrical:
Ignition system, lighting, charging system, wiring diagrams, troubleshooting electrical faults
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, spark plug service, air filter cleaning/replacement, chain adjustment, brake pad inspection, tire pressure checks, coolant level checks, valve clearance (if applicable to the specific engine design of this era).
Repair And Rebuild:
Engine disassembly/assembly, carburetor tuning and rebuilding, clutch component replacement, transmission gear inspection and replacement, brake system bleeding and component replacement, suspension fork seal replacement, wheel bearing replacement, steering head bearing service.
Troubleshooting:
Diagnostic procedures for common running issues, electrical faults, and mechanical failures. Includes symptom-based troubleshooting guides.
Technical Depth
Depth:
Comprehensive, covering everything from basic adjustments and fluid changes to complete engine and transmission rebuilds. Detailed specifications, torque values, and diagnostic procedures are included.
📊 Manual Specifications
File Format
File Format Details:
PDF. High resolution for clarity. Likely text-searchable for quick information retrieval. Printable pages.
Print Quality
Quality:
Excellent. Clear diagrams, schematics, and text. Designed for easy comprehension by technicians and skilled DIYers.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Type:
Two-stroke, liquid-cooled, single-cylinder
Displacement Kx125:
124 cc (approx.)
Displacement Kx250:
249 cc (approx.)
Bore Stroke Kx125:
Varies by specific year, typically around 54.0 mm x 54.5 mm
Bore Stroke Kx250:
Varies by specific year, typically around 66.4 mm x 72.0 mm
Performance
Power Delivery:
Aggressive powerband characteristic of performance two-strokes. Specific horsepower figures are not provided here but are documented in the manual.
Fuel System
Carburetor Kx125:
Typically Keihin PWK Series (e.g., 35mm or 38mm)
Carburetor Kx250:
Typically Keihin PWK Series (e.g., 38mm or 39mm)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Premix:
Requires 2-stroke oil premixed with gasoline at a specified ratio (e.g., 40:1 or 50:1, check manual for exact specification)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Optional
Clutch Type:
Wet, multi-plate
Features
Gear Ratios:
Specific gear ratios are detailed in the manual for each model year and can vary slightly.
Transmission Oil Spec:
Kawasaki-specified gear oil or equivalent (e.g., SAE 80 or 10W-30 API GL-4)
📐 Dimensions
Exterior
Wheelbase:
Varies by year and model, approximately 57-58 inches
Weights
Dry Weight Kx125:
Approximately 200-205 lbs
Dry Weight Kx250:
Approximately 215-220 lbs
🛡️ Safety Features
Ratings
Certification:
Not applicable (motorcycles intended for off-road/competition use, not road legal).
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Passive Features
Frame Construction:
Strong perimeter frame designed for torsional rigidity and impact resistance in demanding off-road conditions.
💡 Technology Features
Infotainment
Features:
N/A (Competition motocross motorcycles).
Driver Assistance
Features:
N/A (Competition motocross motorcycles).
Connectivity
Features:
N/A (Competition motocross motorcycles).
Engine Management
Kips System:
Kawasaki Integrated Power Valve System (KIPS) - Variable exhaust port timing system to optimize power delivery across the RPM range. The manual details its operation, maintenance, and adjustment.
🔧 Maintenance
Service Intervals
Oil Change:
Every 8-15 hours of riding, or as specified in the manual for specific conditions.
Air Filter:
Clean or replace every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug:
Inspect and clean/replace as needed, typically every 20-30 hours of riding.
Top End Rebuild:
Recommended every 40-60 hours of riding for optimal performance, depending on usage and maintenance.
Fluid Specifications
Engine Oil:
Not applicable (2-stroke oil is premixed with fuel). Transmission oil specified separately.
Coolant:
Mixture of distilled water and antifreeze (ethylene glycol based) with anti-corrosion additives. Specific type and ratio detailed in manual.
Brake Fluid:
DOT 4 hydraulic brake fluid
Known Issues
Common Wear Items:
Piston rings, clutch plates, spark plugs, chain and sprockets, fork seals, wheel bearings, and suspension linkages are common wear items due to the demanding nature of motocross.
Carburetor Fouling:
Carburetors can be susceptible to clogging from fuel deposits or dirt ingress if not properly maintained. Regular cleaning and proper air filter maintenance are crucial.
Power Valve System:
The KIPS system (Kawasaki Integrated Power Valve System) requires periodic inspection and cleaning of the carbon buildup to ensure optimal performance.
Suspension Maintenance:
Fork seals and bushings wear over time, requiring replacement to prevent oil leaks. Rear shock linkages and bearings need periodic greasing and inspection.
📚 Vehicle History
Brand Heritage
Kawasaki Motocross:
Kawasaki has a long and successful history in motocross racing, with the KX line consistently being a competitive force.
Model Evolution
Kx Line Evolution:
The KX125 and KX250 models underwent continuous development, incorporating advancements in suspension, engine technology (like KIPS - Kawasaki Integrated Power Valve System), and chassis design throughout the 1990s and early 2000s.
Production
Production Period:
The KX125 and KX250 were produced for many years, with the 1999-2002 generation representing a specific technological iteration.
🏆 Awards & Recognition
Recognitions
Motocross Championships:
The KX line has a strong racing pedigree and has been used to win numerous professional motocross championships worldwide.
Ratings
Performance Reviews:
Consistently reviewed positively by motorcycle journalists and racers for their performance, handling, and durability in their class.
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