This manual covers the models from the 1999 to 2002 production years. These motorcycles represent a significant part of a renowned motocross heritage, built for high performance and competitive racing. Known for their potent two-stroke engines, lightweight chassis, and advanced suspension systems for their era, the series has a strong legacy in off-road motorsports. This guide is designed to assist owners and technicians in understanding and maintaining these capable machines.
The scope of this workshop service repair manual is comprehensive, providing detailed instructions for a wide range of maintenance and repair procedures. It includes information on engine systems, drivetrain, chassis components, and the electrical system, with specific coverage of engine top end, lubrication, fuel, cooling, clutch, final drive, wheels, tires, brakes, suspension, steering, and frame. The manual details routine inspections, fluid changes, filter replacements, engine rebuilds, transmission overhauls, carburetor tuning, suspension work, brake servicing, and electrical troubleshooting, along with essential torque specifications and wiring diagrams.
Model Codes:
KX125-L1, KX250-L1 (1999); KX125-L2, KX250-L2 (2000); KX125-L3, KX250-L3 (2001); KX125-L4, KX250-L4 (2002)
Target Audience:
Owners of 1999-2002 Kawasaki KX125 and KX250 motorcycles, DIY enthusiasts, independent repair shops
Value Proposition:
Provides essential information for DIY maintenance and repair, saving significant costs compared to professional servicing. Offers a comprehensive resource for understanding and working on the vehicles.
Manual Benefits:
Instant download, printable pages, high-quality diagrams, covers a wide range of repair and maintenance tasks.
Download Delivery:
Instant download, eliminating shipping costs and wait times.
Covered Years:
1999, 2000, 2001, 2002
Covered Models:
Kawasaki KX125, Kawasaki KX250
Estimated Page Count:
Likely between 300-600 pages (typical for comprehensive workshop manuals)
Manual Type:
Workshop Service Repair Manual
Digital Format:
PDF (Downloadable)
Compatibility:
Compatible with all versions of Windows & Mac, APP ISO, iPhone, iPod, Android, etc. (Requires Adobe PDF Reader)
Engine Systems:
General Information, Engine Top End, Engine Lubrication System, Crankshaft/Transmission, Fuel System, Cooling System
Drivetrain Systems:
Clutch, Final Drive
Chassis Systems:
Wheels/Tires, Brakes, Suspension, Steering, Frame
Electrical Systems:
Electrical System
Appendix Content:
Often includes specifications, special tool information, and troubleshooting guides not fitting into other categories.
Maintenance Procedures:
Periodic Maintenance, Routine Inspections, Fluid Changes, Filter Replacements, Chain Adjustment
Repair Procedures:
Engine Rebuilds, Transmission Overhaul, Carburetor Tuning, Suspension Overhaul, Brake System Service, Electrical Troubleshooting
Diagnostic Procedures:
Troubleshooting Guides for Common Issues, Symptom-Based Diagnostics
Assembly Disassembly:
Detailed instructions for engine, transmission, suspension, and chassis component removal and installation.
Depth Of Coverage:
Comprehensive (from basic maintenance to complete engine and chassis overhauls)
Torque Specifications:
Includes critical torque values for fasteners to ensure proper assembly and prevent damage.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams for troubleshooting and repair.
Print Quality:
High-quality diagrams and instructions (as stated in description)
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download, printable pages)
Engine Type Kx125:
Liquid-cooled, 2-stroke, single-cylinder
Engine Type Kx250:
Liquid-cooled, 2-stroke, single-cylinder
Bore Stroke Kx125:
Typically around 54.0 x 54.5 mm (verify with specific model year data if available in manual)
Bore Stroke Kx250:
Typically around 66.4 x 72.0 mm (verify with specific model year data if available in manual)
Estimated Horsepower Kx125:
Around 35-40 HP (varies by year and tuning)
Estimated Horsepower Kx250:
Around 45-50 HP (varies by year and tuning)
Carburetor Kx125:
Typically a Keihin PWK series (e.g., 35mm)
Carburetor Kx250:
Typically a Keihin PWK series (e.g., 38mm)
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended
Oil Mixture:
Pre-mix 2-stroke oil (50:1 or 32:1 ratio, consult manual for specific recommendation)
Engine Cooling System:
Liquid-cooled with radiator and fan (often electric fan on later models).
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Kick Starter:
Standard kick-start mechanism for engine starting.
Transmission Type:
6-speed manual, constant mesh
Clutch Type:
Wet, multi-disc
Dry Weight Kx125:
Around 93 kg (205 lbs) for the L1 model
Dry Weight Kx250:
Around 97 kg (214 lbs) for the L1 model
Fuel Capacity Approx:
Around 8.0 Liters (2.1 US gal)
Safety Ratings:
N/A (Motorcycle safety is based on design, rider skill, and protective gear, not formal crash ratings like cars)
Braking System:
Front and Rear Disc Brakes
Chassis Design:
Strong perimeter frame for stability and rigidity
Infotainment Systems:
N/A (Performance motocross bikes of this era do not feature infotainment systems)
Driver Assistance Features:
N/A
Connectivity Features:
N/A
Oil Change Interval:
Frequent oil changes for premix are inherent to 2-stroke operation. Gearbox oil changes typically every 10-20 hours of use or annually.
Air Filter Cleaning:
Should be cleaned or replaced after every few rides, especially in dusty conditions.
Spark Plug Inspection:
Inspect regularly (e.g., every 5-10 hours) and replace as needed. Consult manual for recommended plug type and gap.
Clutch Adjustment:
Regular clutch lever free play adjustment is crucial for proper clutch operation.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment are vital for drivetrain longevity and performance.
Coolant Type:
High-quality ethylene glycol-based coolant with corrosion inhibitors (e.g., 50/50 mix with distilled water)
Gearbox Oil Type:
Specific motorcycle gear oil, typically SAE 80W-90 or 10W-40 (refer to manual for exact specification and capacity).
Common Wear Items:
Piston rings, piston, clutch plates, chain and sprockets, wheel bearings, steering head bearings, fork seals.
Two Stroke Considerations:
Requires diligent attention to fuel/oil mixture, air filter maintenance, and regular top-end inspection/rebuilds for optimal performance and longevity.
Gearbox Oil Capacity Approx:
Around 0.7 - 0.9 Liters (verify with manual)
Coolant Capacity Approx:
Around 0.5 - 0.7 Liters (verify with manual)
Kawasaki Motorsports Legacy:
Kawasaki has a long and successful history in motocross and off-road racing, with the KX line being a cornerstone of their performance offerings.
Kx125 Kx250 Era:
The late 1990s and early 2000s were a competitive era for 125cc and 250cc two-stroke motocross bikes. Kawasaki consistently updated their KX models to remain competitive.
Kx125 Kx250 Performance Focus:
These models were designed for competitive motocross, emphasizing light weight, powerful two-stroke engines, and advanced suspension for their time.
Kx250 Evolution Note:
The KX250 underwent significant development during this period, with changes to engine porting, suspension, and chassis geometry to improve power delivery and handling.
Production Period:
The KX125 and KX250 were produced for many years, with this manual covering the specific 1999-2002 generation.
