Target Audience:
Enthusiasts, DIY mechanics, and professional technicians working on 1994-1998 Kawasaki KX125 and KX250 models.
Value Proposition:
Provides comprehensive factory-level repair and maintenance information, saving significant cost compared to dealership service.
Manual Comparison:
Offers more detailed and actionable information than generic repair guides, comparable to official Kawasaki workshop manuals.
Features:
Factory-originated data, detailed illustrations, comprehensive troubleshooting, and high degree of technical accuracy.
Engine Overhaul:
Complete teardown and rebuild procedures for both KX125 and KX250 engines.
Chassis Maintenance:
Includes suspension, frame, wheels, brakes, and controls.
Electrical System:
Covers ignition, lighting, and charging systems.
Fuel System:
Detailed information on carburetor and fuel delivery.
Cooling System:
Radiator and coolant system maintenance and troubleshooting.
Type:
Factory Service Manual / Repair Manual
Primary Language:
English
Delivery Format:
PDF (Instant Download)
Searchability:
Searchable text content
Navigation:
Clickable chapters
Usage Rights:
No restrictions on printing or saving/burning to disc
Engine:
Complete engine disassembly, assembly, tuning, and troubleshooting. Includes piston, crankshaft, connecting rod, cylinder, cylinder head, crankshaft seals, engine bearings, and more.
Transmission:
Gearbox inspection, maintenance, and repair. Includes gear selection, clutch operation, and related components.
Carburetion:
Detailed carburetor adjustment, cleaning, jetting, and troubleshooting. Covers main jet, pilot jet, slow jet, mixture screw adjustments.
Suspension Front:
Front fork service, including oil changes, seal replacement, and damper adjustments.
Suspension Rear:
Rear shock absorber and linkage system service, maintenance, and adjustment.
Brakes:
Front and rear brake system maintenance, including pad replacement, caliper service, fluid bleeding, and rotor inspection.
Electrical:
Ignition system troubleshooting (no spark, starting issues), CDI unit, stator, magneto, wiring diagrams, battery, and lighting.
Cooling:
Radiator inspection, coolant fluid specifications, flushing procedures, and troubleshooting leaks.
Exhaust:
Exhaust pipe and muffler inspection and maintenance.
Bodywork:
Plastic fairing removal and installation, seat, tank, and fender components.
Routine Maintenance:
Pre-ride checks, oil changes, filter cleaning/replacement, chain adjustment, spark plug maintenance.
Engine Rebuild:
Step-by-step guide for complete engine disassembly and reassembly, including piston, rings, and bearing replacement.
Suspension Service:
Fork oil replacement, seal installation, shock absorber rebuild procedures.
Carburetor Tuning:
Detailed instructions for adjusting air-fuel mixture, idle speed, and jetting for optimal performance and altitude.
Troubleshooting:
Comprehensive diagnostic charts and procedures for common problems like hard starting, loss of power, and electrical faults.
Torque Specifications:
Accurate torque values for critical fasteners across all systems.
Part Diagrams:
Illustrated diagrams of all major components for easy identification and assembly reference.
Level Of Detail:
Extensive, covering from basic maintenance to complete engine and chassis overhauls.
Diagnostic Capability:
Advanced troubleshooting guides for identifying and resolving complex mechanical and electrical issues.
Rebuild Guidance:
Detailed, step-by-step instructions for rebuilding major components like the engine and suspension.
Kx125 Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Kx250 Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Kx125 Displacement:
124 cc (approx.)
Kx250 Displacement:
249 cc (approx.)
Kx125 Bore X Stroke:
Refer to manual for specific dimensions
Kx250 Bore X Stroke:
Refer to manual for specific dimensions
Kx125 Compression Ratio:
Refer to manual for specific figures
Kx250 Compression Ratio:
Refer to manual for specific figures
Kx125 Horsepower:
Varies by model year, typically 35-40 HP (estimated)
Kx250 Horsepower:
Varies by model year, typically 45-50 HP (estimated)
Carburetor Type:
Mikuni VM Series (specific model varies by year)
Fuel Type:
Unleaded gasoline (minimum octane rating specified in manual)
Premix Ratio:
Refer to manual for specific 2-stroke oil to gasoline ratio (e.g., 32:1, 40:1)
Ignition System:
CDI (Capacitor Discharge Ignition) with magneto
Overall Length:
Varies by model year; consult manual for specific measurements.
Overall Width:
Varies by model year; consult manual for specific measurements.
Overall Height:
Varies by model year; consult manual for specific measurements.
Dry Weight:
Varies by model year and specific KX variant, typically around 95-105 kg (209-231 lbs).
Curb Weight:
Includes all necessary fluids and a full tank of fuel; consult manual for exact figures.
Fuel Tank Capacity:
Typically around 8-10 liters (2.1-2.6 gallons).
Oil Change Engine:
Refer to manual; typically after every few races or a set number of riding hours, depending on usage.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions; consult manual for specific intervals.
Spark Plug Inspection:
Inspect and clean/replace as needed, based on performance and manual recommendations.
Chain Lubrication Adjustment:
Regular lubrication and tension adjustment is critical for drivetrain longevity.
Suspension Service:
Fork oil changes and seal checks recommended every 20-40 hours of use; full suspension rebuild intervals vary.
Engine Oil Type:
Dedicated 2-stroke premix oil (specific brand/type recommended by Kawasaki, consult manual).
Transmission Fluid Type:
SAE 80W or 10W-30 gear oil (specific viscosity and API rating detailed in manual).
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (specific mixture ratio and type detailed in manual).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (ensure compatibility; consult manual).
Common Wear Items:
Piston rings, clutch plates, wheel bearings, fork seals, chain and sprockets are common wear items requiring regular inspection and replacement.
Carburetor Clogging:
Can occur due to stale fuel or debris; requires regular cleaning and proper fuel storage.
Ignition System Faults:
Intermittent spark or no spark can indicate CDI, stator, or coil issues, common in older bikes.
Suspension Leaks:
Fork seals and rear shock seals can degrade over time, leading to fluid leaks and reduced damping performance.
Kawasaki Motocross:
Kawasaki has a long and successful history in motocross, with the KX line being a dominant force for decades.
Kx125 Evolution:
The KX125 underwent continuous development during this period, focusing on engine performance, suspension improvements, and chassis geometry for competitive racing.
Kx250 Evolution:
The KX250 also saw significant updates, including engine tuning, revised suspension settings, and chassis refinements to maintain its competitive edge in the highly contested 250cc class.
Manufacturing Location:
Japan (primary manufacturing)
