Kawasaki KX125 KX250 1992-1993 Service Repair Manual

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UGS: 152859

Mots clés: 1992 1993 Kawasaki KX Series KX125 KX250 Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the models from the 1992 and 1993 production years. These two-stroke, liquid-cooled motocross bikes are renowned for their performance and competitive edge in their respective classes. The series has a strong heritage in motocross, known for engineering quality and innovation, with these specific model years representing advancements in suspension and engine capabilities. The 125, with its 124 cc engine, and the 250, featuring a 249 cc engine, offer agile handling and powerful performance, making them popular choices for racing and off-road riding. This comprehensive service repair manual provides detailed information for owners and technicians. It covers all essential systems including General Information, Fuel System, Cooling System, Engine Top End and Bottom End, Transmission, Wheels and Tires, Final Drive, Brakes, Suspension, Steering, and the Electrical System. The manual includes step-by-step repair and rebuild instructions, maintenance procedures, troubleshooting guides, and technical specifications such as torque values and fluid capacities. Its purpose is to assist in maintaining, diagnosing, and repairing these models, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX125, KX250

Model Variants:

KX125, KX250

Year:

1992, 1993

Codes

Chassis Codes:

KX125: KX250-K, KX250: KX250-K

Engine Codes:

KX125: KX250DE, KX250: KX250DE

👋 Introduction

Market Position

Target Audience:

Owners of 1992-1993 Kawasaki KX125 and KX250 motorcycles seeking to perform maintenance, repairs, and diagnostics.

Competitive Analysis

Value Proposition:

Provides dealership-level technical information, enabling cost savings on repairs and maximizing vehicle longevity. Offers step-by-step guidance for complex procedures.

Key Features

Feature 1:

Official factory service manual content, ensuring accuracy and completeness.

Feature 2:

Detailed diagrams, illustrations, and exploded views to aid understanding.

Feature 3:

Troubleshooting sections to help diagnose and resolve issues efficiently.

Feature 4:

Instant download for immediate access to repair information.

📋 Manual Details

Coverage Areas

Systems Covered:

General Information, Fuel System, Cooling System, Engine Top End, Engine Right Side, Engine Removal/Installation, Engine Bottom End/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Electrical System, Appendix

Page Count

Estimated Page Count:

Varies by specific edition, typically 300-600 pages for a comprehensive service manual.

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

File Format:

Print Quality:

Printable (High-resolution PDF)

Compatibility:

Win/Mac

Requirements:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed coverage of top-end (cylinder, piston, rings, head) and bottom-end (crankshaft, connecting rod, bearings, gearbox) assemblies, including disassembly, inspection, repair, and reassembly procedures.

Fuel System:

Carburetor service, jetting, fuel lines, fuel tank, fuel pump (if applicable), and related components.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, and flushing procedures.

Transmission:

Gearbox disassembly, inspection, lubrication, and troubleshooting.

Suspension:

Front fork (KYB or Showa, depending on specific model/variant) disassembly, oil changes, seal replacement, and rear shock absorber service.

Brakes:

Front and rear brake caliper service, master cylinder overhaul, hydraulic line replacement, pad replacement, and bleeding procedures.

Wheels Tires:

Wheel bearing replacement, spoke tensioning, tire mounting/dismounting, and recommended tire pressures.

Final Drive:

Chain and sprocket inspection, adjustment, and replacement.

Steering:

Steering stem bearing service, linkage inspection, and handlebar alignment.

Electrical System:

Ignition system, lighting, wiring diagrams, troubleshooting electrical faults, and component testing.

Procedures Included

Maintenance:

Regular service checks, oil changes, filter replacements, lubrication points, and adjustments.

Troubleshooting:

Diagnostic flowcharts, symptom analysis, and identification of common problems with solutions.

Repair Rebuild:

Step-by-step instructions for disassembling, repairing, and reassembling all major components and systems.

Technical Specifications:

Torque specifications for critical fasteners, clearance measurements, engine tuning data, and fluid capacities.

Technical Depth

Depth:

Comprehensive, covering everything from basic routine maintenance to complete engine and chassis overhauls. Suitable for both amateur and professional mechanics.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Binding Type

Binding:

Digital Download (PDF)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, Liquid-Cooled

Kx125 Displacement:

124 cc (7.58 cu in)

Kx250 Displacement:

249 cc (15.2 cu in)

Bore X Stroke Kx125:

56.0 x 49.2 mm (2.20 x 1.94 in)

Bore X Stroke Kx250:

68.4 x 68.5 mm (2.69 x 2.70 in)

Compression Ratio Kx125:

Approx. 8.7:1 (stock)

Compression Ratio Kx250:

Approx. 7.8:1 (stock)

Performance

Horsepower Kx125:

Estimates vary, typically around 30-35 HP at the crank.

Horsepower Kx250:

Estimates vary, typically around 40-45 HP at the crank.

Fuel System

Carburetor Kx125:

Keihin PWK35 (typically)

Carburetor Kx250:

Keihin PWK38 (typically)

Fuel Type:

Unleaded gasoline with 2-stroke oil mix (e.g., 50:1 ratio, refer to manual for exact specification)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet multi-plate

Final Drive Type:

Chain Drive

Gear Oil Specification:

Refer to manual for specific SAE viscosity grade (e.g., SAE 80 or SAE 90 gear oil).

📐 Dimensions

Exterior

Wheelbase Kx125:

Approx. 1445 mm (56.9 in)

Wheelbase Kx250:

Approx. 1475 mm (58.1 in)

Weights

Dry Weight Kx125:

Approx. 93 kg (205 lbs)

Dry Weight Kx250:

Approx. 105 kg (231 lbs)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable (motorcycle)

Active Features

Active Safety:

Powerful disc brakes, responsive suspension, agile handling.

Passive Features

Passive Safety:

Robust frame construction.

💡 Technology Features

Infotainment

Infotainment System:

N/A (basic motocross bike)

Driver Assistance

Driver Assistance Features:

N/A (basic motocross bike)

Connectivity

Connectivity Options:

N/A (basic motocross bike)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for recommended hours/miles for gearbox oil and fork oil changes.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions.

Chain Lubrication Adjustment:

Regular lubrication and tension adjustment are critical for longevity and performance.

Fluid Specifications

Engine Oil Mix:

Specific 2-stroke oil and mix ratio detailed in manual (commonly 50:1).

Coolant Type:

Ethylene glycol-based coolant, mixed with distilled water.

Fork Oil Viscosity:

Refer to manual for specific viscosity grade (e.g., SAE 5W, SAE 10W).

Known Issues

Common Issue 1:

Wear on the clutch plates and baskets due to high-performance use.

Common Issue 2:

Piston ring wear and potential cylinder scoring if maintenance is neglected.

Common Issue 3:

Leaking fork seals due to rough usage and impact.

Common Issue 4:

Carburetor jetting adjustments may be needed for different altitudes or conditions.

📚 Vehicle History

Brand Heritage

Brand Heritage:

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

Model Evolution

Kx125 Evolution:

The 1992-1993 KX125 was part of a generation that saw significant advancements in suspension technology (e.g., USD forks) and engine performance, building on earlier models.

Kx250 Evolution:

The 1992-1993 KX250 continued Kawasaki's strong presence in the 250cc motocross class, often featuring competitive chassis and engine packages for its era.

Production

Production Era:

1992-1993

🏆 Awards & Recognition

Recognitions

Motocross Performance:

Kawasaki KX models have consistently received accolades and race wins in their respective classes during this era.

Ratings

Magazine Reviews:

Contemporary motorcycle magazines of the era often praised the KX series for their power, handling, and race-bred capabilities.

Certifications

Manufacturing Standards:

Manufactured to Kawasaki's strict quality control standards.