2003-2008 Kawasaki KX125 + KX250 Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 131268

Mots clés: 2003 2004 2005 2006 2007 2008 Kawasaki KX Series KX125 KX250 Motorcycle Motorcycles

Variantes de produits

Description

This manual provides comprehensive service, repair, and maintenance information for the KX125 and KX250 motorcycles, covering chassis codes M1, M2, M3, M6F, M7F, and M8F. These competition motocross motorcycles are known for their aggressive, race-bred powerbands and agile handling, building on a long and storied legacy in motorsports. The KX125 and KX250 have historically been dominant forces, winning numerous championships and serving as benchmarks in their respective classes. This Factory Service Repair Workshop Manual offers detailed guidance across all major systems, including engine, drivetrain, chassis, and electrical components. It covers essential maintenance procedures, such as fluid checks and changes, filter replacements, and adjustments, alongside in-depth repair instructions for engine overhauls, clutch service, suspension work, and more. The manual also provides crucial diagnostic information to help owners, DIY mechanics, and professional technicians accurately identify and resolve issues, ensuring optimal performance and longevity of these iconic two-stroke machines.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX125 & KX250

Model Variants Covered:

KX125-M1, KX250-M1, KX125-M2, KX250-M2, KX125-M3, KX125M6F, KX125M7F, KX125M8F

Codes

Chassis Codes Kx125:

M1, M2, M3, M6F, M7F, M8F

Chassis Codes Kx250:

M1, M2

👋 Introduction

Market Position

Target Audience:

Owners, DIY mechanics, and professional technicians seeking accurate and detailed repair and maintenance information for Kawasaki KX125 and KX250 motorcycles.

Competitive Analysis

Value Proposition:

Provides the same authoritative, manufacturer-sourced information that professional technicians rely on, enabling significant cost savings and deeper understanding of the vehicle.

Key Features

Manufacturer Origin:

Original Factory Service Repair Workshop Manual

Information Accessibility:

Easy access to comprehensive diagnostic, repair, and maintenance information at the click of a mouse.

📋 Manual Details

Coverage Areas

Manual Scope:

Comprehensive service, repair, and maintenance information for the specified Kawasaki KX models.

Page Count

Page Count:

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

File Format:

Compatibility

Operating Systems:

All Versions of Windows & Mac

Requirements

Software Requirements:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Systems:

General Information, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Crankshaft/Transmission

Drivetrain Systems:

Clutch, Crankshaft/Transmission, Final Drive

Chassis Systems:

Wheels/Tires, Brakes, Suspension, Steering, Frame

Electrical Systems:

Electrical System, Wiring Diagrams (implied by 'Wiring Diagrams' in description)

Procedures Included

Maintenance Procedures:

Periodic Maintenance, Fluid Checks and Changes, Filter Replacements, Adjustments

Repair Procedures:

Engine Top End Overhaul, Clutch Service, Crankshaft and Transmission Rebuild, Brake System Bleeding and Service, Suspension Component Overhaul, Steering Assembly Disassembly and Reassembly

Diagnostic Procedures:

Detailed diagnostic information for identifying and resolving issues across all vehicle systems.

Technical Depth

Depth Of Coverage:

Comprehensive; includes detailed diagrams, specifications, and step-by-step instructions for professional technician-level repairs and maintenance.

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Print Quality

Image Resolution:

High-resolution, suitable for clear viewing of diagrams and text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type Kx125:

Liquid-cooled, 2-stroke, single-cylinder

Bore Stroke Kx125 Approx:

54.0 x 54.5 mm (Note: Specific bore/stroke varies slightly across years, but this is representative for the generation)

Displacement Kx125:

124 cm³

Engine Type Kx250:

Liquid-cooled, 2-stroke, single-cylinder

Bore Stroke Kx250 Approx:

66.4 x 72.0 mm (Note: Specific bore/stroke varies slightly across years, but this is representative for the generation)

Displacement Kx250:

249 cm³

Performance

Power Delivery Characteristics:

Aggressive, race-bred powerbands typical of modern 2-stroke motocross engines.

Fuel System

Carburetion Kx125:

Keihin PWK38 (typical for this generation, check manual for exact year specification)

Carburetion Kx250:

Keihin PWK39 (typical for this generation, check manual for exact year specification)

Fuel Type:

Unleaded gasoline (premium recommended)

Oil Mixing:

Pre-mix (2-stroke engine oil) in fuel; specific ratio detailed in manual.

🔧 Transmission

Standard

Transmission Type:

5-speed manual transmission

Features

Clutch Type:

Multi-plate wet clutch

📐 Dimensions

Weights

Dry Weight Kx125 Approx:

94.0 kg (207.2 lbs) (Varies slightly by year)

Dry Weight Kx250 Approx:

101.0 kg (222.7 lbs) (Varies slightly by year)

Fuel Capacity Approx:

8.0 L (2.1 US gal)

🛡️ Safety Features

Ratings

Safety Classification:

Competition Motocross Motorcycle (not street legal)

Active Features

Braking System Front:

Hydraulic disc brake

Braking System Rear:

Hydraulic disc brake

💡 Technology Features

Infotainment

Infotainment System:

N/A (Competition Motocross Motorcycle - no infotainment system)

Driver Assistance

Driver Assistance Features:

N/A (Competition Motocross Motorcycle - no electronic driver assistance)

Connectivity

Connectivity Features:

N/A (Competition Motocross Motorcycle - no connectivity features)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Detailed recommendations for engine oil and gearbox oil changes based on operating hours or mileage, provided within the manual.

Spark Plug Maintenance:

Recommended inspection and replacement intervals for spark plugs.

Air Filter Cleaning:

Frequent cleaning and oiling of the air filter is critical for 2-stroke performance; manual will specify procedures.

Fluid Specifications

Engine Oil Type:

Specific 2-stroke engine oil recommendations (e.g., JASO FD or higher) and mixing ratios detailed in the manual.

Gearbox Oil Type:

Specific gearbox oil specifications (e.g., SAE 10W40 API GL-4) will be listed.

Coolant Type:

Mixture of antifreeze and distilled water (specific ratio and type provided).

Known Issues

Common Wear Items:

Piston and rings wear due to high-revving nature, clutch wear, chain and sprockets wear, suspension seal leaks.

Power Valve Maintenance:

The power valve system requires regular cleaning and lubrication to ensure optimal engine performance and prevent sticking.

Carburetor Tuning:

Proper jetting and adjustment of the carburetor are crucial for performance and can be affected by altitude and temperature; manual provides guidance.

📚 Vehicle History

Brand Heritage

Kawasaki Motorsports Legacy:

Kawasaki has a long and storied history in motocross racing, with the KX line being a dominant force in professional and amateur competition.

Model Evolution

Kx125 Generation Overview:

The 2003-2008 KX125 represents a mature stage of this highly competitive 125cc two-stroke motocross bike, known for its strong powerband and agile handling. Updates during this period focused on chassis refinements, suspension improvements, and engine tuning for enhanced performance.

Kx250 Generation Overview:

The KX250 models covered (2003-2004) are part of the last generation of the highly regarded liquid-cooled, two-stroke KX250. This era was known for its potent engine and capable chassis, a benchmark in the 250cc class before the transition to four-stroke technology.

Production

Production Period Kx250 2Stroke:

The KX250 2-stroke production ceased after the 2007 model year in most markets, with the 2008 model year primarily featuring the 250F. This manual covers the final years of this iconic 2-stroke model.

🏆 Awards & Recognition

Recognitions

Motocross Industry Standing:

The KX125 and KX250 have historically been highly regarded and successful platforms in motocross racing, winning numerous championships and accolades.