Kawasaki KX125/KX250 Service Manual Repair 1990-1991 KX 125 250

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Tipo: Motorcycle

Proveedor:

SKU: 134179

Etiquetas: 1990 1991 Kawasaki KX Series KX125 KX250 Motorcycle Motorcycles

Variantes de producto

Descripción

The Kawasaki KX125 and KX250 models from 1990-1991 represent a significant chapter in motocross engineering. These two-stroke machines were renowned for their potent engines and agile chassis, designed to excel in competitive off-road environments. Built in Japan, Kawasaki’s heritage in motocross racing is evident in the performance and durability of these dirt bikes, which competed directly with other leading manufacturers of the era. With liquid-cooled, single-cylinder engines, 6-speed transmissions, and robust suspension systems providing substantial travel, the KX series was engineered for riders seeking peak performance and a competitive edge. This comprehensive factory service manual provides essential information for the maintenance, repair, and troubleshooting of your 1990-1991 Kawasaki KX125 and KX250 motorcycles. Covering everything from detailed engine disassembly and reassembly, transmission overhauls, and fuel system adjustments to electrical system diagnostics and suspension servicing, this manual is an indispensable resource. It includes critical technical specifications, torque values, fluid recommendations, and clear, step-by-step procedures designed to assist both experienced technicians and dedicated owners in keeping these high-performance machines in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX125 / KX250

Model Years Covered:

1990-1991

Codes

Chassis Codes Kx125:

KX125-K1, KX125-K2

Chassis Codes Kx250:

KX250-K1, KX250-K2

👋 Introduction

Market Position

Positioning:

The Kawasaki KX series of the late 80s and early 90s were highly competitive motocross machines, known for their potent two-stroke power and agile handling. This manual serves as an essential tool for owners and mechanics to maintain and repair these performance-oriented dirt bikes.

Competitive Analysis

Competitors:

Competed directly with Yamaha YZ series, Honda CR series, and Suzuki RM series motocross bikes of the same era.

Key Features

Manual Value:

Provides factory-accurate information, covering all aspects of the vehicle necessary for proper maintenance and repair, including detailed diagrams and torque specifications that are critical for two-stroke engine longevity.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete factory repair and service for 1990-1991 Kawasaki KX125 and KX250 two-stroke motorcycles.

Secondary Coverage:

Maintenance, troubleshooting, diagnostics, part identification, technical specifications, and procedures.

Page Count

Page Count:

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

Searchability:

Searchable PDF, allowing users to quickly locate specific information.

Navigation:

Clickable chapters for easy navigation through the manual's content.

Restrictions:

No restrictions on printing or saving/burning to disc.

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, and repair of both KX125 and KX250 two-stroke engines, including top-end, bottom-end, piston, rings, cylinder, crankshaft, connecting rod, seals, and bearings.

Transmission Drivetrain:

Detailed procedures for transmission disassembly, assembly, inspection, gear inspection, shift drum and forks, primary reduction gear, and clutch assembly.

Fuel System:

Carburetor tuning, jetting information, disassembly, cleaning, and reassembly, fuel tank, fuel lines, and fuel pump (if applicable).

Ignition Electrical:

Ignition system components, CDI unit, magneto, stator, ignition timing, troubleshooting 'no spark' issues, wiring diagrams, switches, and lights.

Cooling System:

Radiator, coolant hoses, coolant change procedures, and troubleshooting overheating.

Suspension Front:

Front fork disassembly, assembly, oil change, seal replacement, spring inspection, damping adjustments, and calibration.

Suspension Rear:

Monoshock rear suspension service, shock absorber disassembly, inspection, sealing, linkage maintenance, and adjustment procedures.

Brakes:

Front and rear brake system service, caliper disassembly, piston inspection, pad replacement, brake fluid flush and bleeding, rotor inspection, and master cylinder service.

Wheels Tires:

Wheel bearing inspection and replacement, spoke tensioning, tire inspection and replacement, and recommended tire pressures.

Frame Bodywork:

Frame inspection, handlebar replacement, plastic panel removal and installation, seat service, and fender replacement.

Procedures Included

Maintenance:

Scheduled maintenance tasks, lubrication points, chain adjustment, air filter cleaning/replacement, spark plug service, and general upkeep.

Troubleshooting:

Extensive troubleshooting guides for common problems such as starting issues, poor performance, engine noises, electrical faults, and suspension irregularities.

Repair Rebuild:

Comprehensive step-by-step instructions for complete engine teardowns and rebuilds, transmission overhauls, and component-specific repairs.

Diagnostics:

Diagnostic procedures for identifying the root cause of various mechanical and electrical issues.

Installation:

Instructions for installing specific components or upgrades (implied through part diagrams and assembly procedures).

Technical Depth

Depth:

Detailed, from basic maintenance to complete engine and transmission overhauls. Suitable for DIY enthusiasts and professional mechanics.

Data Types:

Torque specifications, clearances, fluid capacities, electrical specifications, engine data, and dimensional data.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Print Quality Notes:

Assumed high-quality scan suitable for printing, including clear illustrations and diagrams.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine Kx125

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement Kx125:

124 cc

Bore Kx125:

56.0 mm

Stroke Kx125:

49.4 mm

Compression Ratio Kx125:

Approx. 8.0:1 (varies slightly by model year and region)

Primary Engine Kx250

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement Kx250:

249 cc

Bore Kx250:

66.0 mm

Stroke Kx250:

73.0 mm

Compression Ratio Kx250:

Approx. 7.8:1 (varies slightly by model year and region)

Performance

Carburetor Kx125:

Keihin PWK35 (typical for this era)

Carburetor Kx250:

Keihin PWK38 (typical for this era)

Fuel System

Fuel Type:

Unleaded gasoline mixed with 2-stroke engine oil (specific mix ratio in manual)

Recommended Oil Viscosity:

JASO FD or API TC certified 2-stroke oil (specific viscosity recommendations in manual).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh, sequential type

Features

Clutch Type:

Wet, multi-disc, cable-actuated

Final Drive:

Chain drive

📐 Dimensions

Exterior

Front Suspension Travel Kx125:

Approx. 11.8 inches (300 mm)

Rear Suspension Travel Kx125:

Approx. 12.0 inches (305 mm)

Front Suspension Travel Kx250:

Approx. 11.8 inches (300 mm)

Rear Suspension Travel Kx250:

Approx. 12.0 inches (305 mm)

Weights

Dry Weight Kx125:

Approx. 210 lbs (95 kg)

Dry Weight Kx250:

Approx. 225 lbs (102 kg)

🛡️ Safety Features

Ratings

Safety Focus:

Designed for off-road competition; safety features are inherent in the vehicle's design and require proper rider skill and protective gear.

Active Features

Braking System:

Hydraulic disc brakes front and rear for effective stopping power.

Passive Features

Frame Construction:

High-tensile steel perimeter frame providing strength and rigidity.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Competition motocross bike)

Driver Assistance

Driver Assistance Features:

N/A (Competition motocross bike)

Connectivity

Connectivity Features:

N/A (Competition motocross bike)

🔧 Maintenance

Service Intervals

Oil Change Intervals:

Regular oil changes for engine lubrication (pre-mix) and transmission oil changes as per manual recommendations, typically based on operating hours or ride frequency.

Air Filter Cleaning:

Frequent cleaning/replacement, especially in dusty conditions, as per manual recommendations.

Spark Plug Service:

Regular inspection, cleaning, and gap adjustment or replacement as per manual recommendations.

Fluid Specifications

Transmission Oil:

Kawasaki specifically recommends its own brand of Hypoid Gear Oil SAE 80W-90 or equivalent API GL-4 specification. Manual will specify exact quantity.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol-based) mixed with distilled water. Manual specifies ratio.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for precise specification).

Known Issues

Common Wear Items:

Piston rings, clutch plates, wheel bearings, swingarm bearings, and fork seals are common wear items on high-performance motocross bikes of this era.

Two Stroke Specific:

Proper jetting and pre-mix ratios are crucial for engine longevity and performance. Carbon buildup in the exhaust port and power valve (if equipped) can affect performance.

📚 Vehicle History

Brand Heritage

Kawasaki Offroad:

Kawasaki has a long and successful history in motocross racing, with the KX line consistently being a strong contender across various classes.

Model Evolution

Kx Evolution 90 91:

The 1990-1991 models represent a refinement of Kawasaki's motocross technology, featuring improvements in suspension, engine performance, and chassis design from previous generations.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motocross Contributions:

While specific awards for these particular model years might be difficult to pinpoint without detailed historical race results, the KX125 and KX250 were consistently competitive in professional and amateur motocross racing throughout their production cycles.