Kawasaki KX125 & KX250 Motorcycle Complete Workshop Service Repair Manual 1999 2000 2001 2002

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Art.-Nr: 153512

Stichworte: 1999 2000 2001 2002 Kawasaki KX125 KX250 Misc Motorcycle Motorcycles

Produktvarianten

Beschreibung

This workshop service repair manual provides comprehensive guidance for motocross motorcycles manufactured between 1999 and 2002. These models are renowned for their potent liquid-cooled, 2-stroke single-cylinder engines, delivering aggressive, top-end focused powerbands characteristic of high-performance off-road machines. Built with robust steel perimeter frames and featuring advanced suspension systems, including 21-inch front and 19-inch rear spoke wheels, these bikes are engineered for demanding motocross competition. Their legacy is marked by significant racing success and continuous development, making them a dominant force in their respective classes. This manual serves as an essential technical resource, covering all aspects of service, repair, and maintenance. It details procedures for engine disassembly and reassembly, transmission servicing, chassis and suspension adjustments, brake system maintenance, and electrical system troubleshooting. With over 500 pages of information presented in English, it includes detailed diagrams, torque specifications, fluid recommendations, and diagnostic guides for common issues. This comprehensive English-language resource is designed to assist both novice owners and experienced technicians in keeping their motorcycles in optimal working condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX125 / KX250

Product Type:

Workshop Service Repair Manual

Applicable Model Years:

1999, 2000, 2001, 2002

👋 Introduction

Market Position

Positioning:

Essential technical resource for owners and mechanics of the popular Kawasaki KX125 and KX250 motocross bikes from the early 2000s.

Competitive Analysis

Competitors:

Directly competes with factory service manuals and other third-party repair guides for the same model years.

Key Features

Features:

Covers both KX125 and KX250 models, detailed troubleshooting, comprehensive component diagrams, electrical schematics.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service, repair, troubleshooting, and maintenance for Kawasaki KX125 and KX250 motorcycles.

Secondary Coverage:

Includes detailed diagrams, specifications, and procedures for all major mechanical and electrical systems.

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, and repair (cylinder, piston, crankshaft, connecting rod, carburetor, ignition system, cooling system if applicable).

Transmission:

Gearbox disassembly, assembly, inspection, and repair (clutch, shift mechanism, gear ratios, lubrication).

Chassis:

Frame inspection and repair, suspension (front forks, rear shock absorber) disassembly, assembly, and servicing, steering system.

Brakes:

Hydraulic brake system (front and rear), brake caliper servicing, master cylinder servicing, brake pad replacement, brake fluid specifications and bleeding procedures.

Electrical System:

Wiring diagrams, lighting system, ignition system troubleshooting, battery maintenance, charging system, CDI unit.

Fuel System:

Fuel tank, fuel lines, carburetor adjustment and cleaning, jetting information.

Exhaust System:

Exhaust pipe and silencer inspection and replacement.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, air filter cleaning/replacement, spark plug replacement, valve clearance (if applicable, though these are 2-strokes).

Troubleshooting:

Diagnostic guides for common performance issues, starting problems, electrical faults.

Component Rebuild:

Detailed step-by-step instructions for engine, transmission, and suspension component overhauls.

Torque Specifications:

Precise torque values for all critical fasteners.

Technical Depth

Depth:

Comprehensive, suitable for both home mechanics and professional technicians. Covers basic adjustments to complete engine rebuilds.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution scans, clear text, and legible diagrams for easy viewing and printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine Kx125

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

124 cc (7.57 cu. in.)

Bore X Stroke:

54.0 x 54.5 mm (2.13 x 2.15 in)

Carburetion:

Keihin PWK35

Primary Engine Kx250

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

249 cc (15.2 cu. in.)

Bore X Stroke:

66.4 x 72.0 mm (2.61 x 2.83 in)

Carburetion:

Keihin PWK38

Performance

Power Delivery:

Typical aggressive, top-end focused powerbands characteristic of motocross bikes of this era.

Fuel System

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Fuel Mixture:

2-stroke premix (e.g., 32:1 or 40:1 ratio depending on manufacturer's recommendation and oil quality).

Ignition

Ignition System:

Digital CDI (Capacitor Discharge Ignition) with electronic advance.

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed, return shift

Optional

Clutch Type:

Wet, multi-disc, manual operation

Features

Gear Ratios:

Specific gear ratios for both KX125 and KX250 are detailed within the manual.

Final Drive:

Chain drive

Transmission Oil:

Kawasaki motorcycle gear oil 10W-40 or equivalent API GL-4 specification.

📐 Dimensions

Exterior Kx125

Overall Length:

Approximately 2165 mm (85.2 in)

Overall Width:

Approximately 820 mm (32.3 in)

Overall Height:

Approximately 1235 mm (48.6 in)

Exterior Kx250

Overall Length:

Approximately 2165 mm (85.2 in)

Overall Width:

Approximately 820 mm (32.3 in)

Overall Height:

Approximately 1235 mm (48.6 in)

Weights Kx125

Dry Weight:

Approximately 93 kg (205 lbs)

Weights Kx250

Dry Weight:

Approximately 98 kg (216 lbs)

Wheels Tires

Front Wheel:

21-inch spoke wheel

Rear Wheel:

19-inch spoke wheel

Front Tire Size:

80/100-21

Rear Tire Size:

110/90-19 (typical, check manual for variations)

🛡️ Safety Features

Ratings

Safety Ratings:

As a motocross bike, safety ratings are not applicable in the same way as street-legal vehicles. Focus is on structural integrity and component reliability under extreme use.

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear for superior stopping power.

Passive Features

Frame Construction:

Robust steel perimeter frame designed for high-impact absorption and rigidity.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable (Motocross bike).

Driver Assistance

Driver Assistance Features:

Not applicable (Motocross bike).

Connectivity

Connectivity:

Not applicable (Motocross bike).

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Depends on usage; typically after every 5-10 hours of off-road riding or as per manual recommendation.

Air Filter Cleaning:

Frequently, especially in dusty conditions. Daily check recommended for race use.

Chain Adjustment:

As needed, check slack regularly. Refer to manual for specific free play measurement.

Fluid Specifications

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol-based) mixed with distilled water in a 50:50 ratio.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Piston rings, clutch plates, wheel bearings, fork seals, chain and sprockets, spark plugs.

Engine Top End:

Regular top-end rebuilds (piston, rings, cylinder inspection) are essential for maintaining performance in these 2-stroke engines.

Carburetor Issues:

Carburetor clogging or jetting issues due to fuel quality or contamination.

Maintenance Schedule

Schedule Availability:

The manual provides a detailed maintenance schedule based on operating hours or mileage.

📚 Vehicle History

Brand Heritage

Heritage:

Kawasaki has a long and successful history in motocross, with the KX line being a dominant force in competition for decades.

Model Evolution Kx

Evolution Kx125:

The KX125 underwent significant development, moving towards more sophisticated engine designs, improved suspension, and chassis geometry to compete in the highly competitive 125cc class.

Evolution Kx250:

The KX250 has historically been a powerhouse, with Kawasaki investing heavily in performance enhancements, including cylinder porting, exhaust systems, and chassis refinements, to maintain its competitive edge.

Production

Production Era:

These models represent a specific generation of the KX platform, known for their potent engines and race-bred handling.

🏆 Awards & Recognition

Recognitions

Competitive Success:

Kawasaki KX models have historically achieved numerous wins and championships in professional motocross and supercross racing series.

Ratings

Magazine Reviews:

These models were generally well-received by the press for their performance, handling, and competitive pricing in their respective classes.