Target Audience:
Kawasaki KX125 and KX250 owners, mechanics, and enthusiasts seeking detailed repair and maintenance information.
Value Proposition:
Provides comprehensive technical data, diagrams, and procedures essential for maintaining and repairing these high-performance motocross bikes, saving time and money on professional servicing.
Essential Resource:
Indispensable for parts ordering, DIY repairs, and understanding the intricate workings of the KX125/KX250.
Content Highlight:
Covers complete tear-down and rebuild processes with detailed visual aids.
Primary Coverage:
Complete service, repair, maintenance, and troubleshooting for Kawasaki KX125 and KX250 models from 2003 to 2008.
Specific Topics:
Engine disassembly and reassembly, chassis service, electrical systems, suspension, braking, cooling, fuel systems, and more.
Type:
Workshop Manual / Service Repair Manual
Compatibility:
Windows, Mac
Engine:
Complete overhaul, component inspection, lubrication, timing, cooling system, exhaust system.
Transmission:
Clutch operation, gearbox disassembly and reassembly, shift mechanism, lubrication.
Fuel System:
Carburetor tuning and maintenance (Keihin PWK models), fuel lines, fuel tank service.
Suspension:
Front fork (Kayaba/Showa) service, rear shock absorber (Kayaba/Showa) service, spring rates, damping adjustments, seal replacement.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, hydraulic system troubleshooting.
Electrical System:
Ignition system troubleshooting, wiring diagrams, lighting, charging system (if applicable to model variants), spark plug specifications.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm maintenance, linkage lubrication.
Routine Maintenance:
Oil changes, filter cleaning/replacement, chain adjustment, spark plug replacement, air filter service, pre-ride checks.
Component Overhaul:
Full engine rebuild, carburetor rebuild, suspension fork overhaul, brake system component service.
Troubleshooting:
Diagnostic guides for common performance issues, starting problems, electrical faults, and mechanical failures.
Torque Specifications:
Detailed torque values for all critical fasteners across all systems.
Depth Level:
Comprehensive. Covers basic to advanced repair and rebuild procedures.
Visual Aids:
Includes numerous pictures and diagrams for clarity.
Quality:
Digital Adobe PDF format, printable pages.
Printability:
All pages are printable, allowing users to print specific sections for use in the workshop.
Binding:
Digital (PDF) - No physical binding.
Paper Type:
Digital (PDF) - Not applicable to physical paper.
Kx125 Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Kx125 Displacement:
124 cc
Kx250 Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Kx250 Displacement:
249 cc
Engine Breathing:
Case-reed induction
Power Valve System:
Kawasaki Integrated Power Valve System (KIPS)
Lubrication:
Pre-mix (2-stroke oil mixed with gasoline)
Carburetor Kx125:
Keihin PWK37
Carburetor Kx250:
Keihin PWK39
Wheelbase Kx125:
Approx. 58.3 inches (1480 mm)
Wheelbase Kx250:
Approx. 58.3 inches (1480 mm)
Dry Weight Kx125:
Approx. 198.4 lbs (90 kg)
Dry Weight Kx250:
Approx. 213.9 lbs (97 kg)
Fuel Capacity:
Approx. 2.1 US gal (8.0 L)
Oil Change:
Refer to manual for specific intervals based on riding conditions; typically after every few riding sessions for intensive use.
Air Filter Cleaning:
Recommended after every riding day or as needed based on dust/mud conditions.
Spark Plug Replacement:
Recommended based on usage hours, or when fouled/worn.
Engine Oil Type:
2-stroke engine oil meeting API TC, JASO FD, or ISO-L-EGD standards.
Transmission Oil Type:
SAE 10W-30 API GL-4 gear oil or equivalent motorcycle transmission oil.
Coolant Type:
Permanent type (antifreeze) coolant, mixture of 50% ethylene glycol and 50% distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Clutch Wear:
Common to high-performance 2-strokes; clutch plates and springs may require periodic replacement.
Suspension Seals:
Fork seal leaks can occur with aggressive use; regular inspection and replacement is advised.
Power Valve System Fouling:
KIPS system can accumulate carbon buildup, requiring periodic cleaning to maintain optimal performance.
Kawasaki Motocross:
Kawasaki has a long and storied history in motocross racing, with the KX series being a cornerstone of their off-road performance lineup.
Kx125 Evolution Period:
The 2003-2008 models represent a significant evolution in the KX125, incorporating advancements in chassis design, engine performance, and suspension technology from previous generations.
Kx250 Evolution Period:
The KX250 during this period saw continuous refinements, building on its reputation for strong power delivery and competitive chassis dynamics.
Production Era:
These models are part of the highly competitive '00s era of motocross, where technology rapidly advanced.
