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2003-2008 Kawasaki KX125 KX250 Service Repair Manual

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This manual covers the KX125 and KX250 models produced between 2003 and 2008. These highly regarded motocross bikes are known for their powerful two-stroke engines, advanced suspension, and competitive chassis,...
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2003-2008 Kawasaki KX125 KX250 Service Repair Manual
This manual covers the KX125 and KX250 models produced between 2003 and 2008. These highly regarded motocross bikes are known for their powerful two-stroke engines, advanced suspension, and competitive chassis, making them a favorite for racing and aggressive trail riding. The long-standing legacy in motocross is evident in the performance and engineering of these machines, which were designed to excel in demanding off-road conditions. Throughout their production years, these models received updates aimed at enhancing their already formidable capabilities. This comprehensive Service Repair Manual provides detailed information essential for the maintenance, repair, and troubleshooting of your KX125 or KX250. It covers a wide array of systems, including engine components such as the fuel system, cooling system, and internal engine parts, as well as chassis elements like the brakes, suspension, and frame. Additionally, it delves into the electrical system and offers in-depth procedures for assembly, disassembly, and diagnostics. This resource is invaluable for owners, mechanics, and technicians seeking to maintain the peak performance and reliability of their motorcycles.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX125/KX250
Model Years Covered:
2003, 2004, 2005, 2006, 2007, 2008
Codes
Kx125 Model Codes:
M1 (2003), M2 (2004), M3 (2005), M6F (2006), M7F (2007), M8F (2008)
Kx250 Model Codes:
M1 (2003), M2 (2004)
👋 Introduction
Market Position
Target Audience:
Owners, mechanics, and enthusiasts of 2003-2008 Kawasaki KX125 and KX250 dirt bikes.
Competitive Analysis
Manual Advantage:
Provides exhaustive repair information, often exceeding basic owner's manuals, crucial for maintaining performance of these specialized motocross bikes.
Key Features
Download Benefits:
Instant download, no shipping costs, no waiting for physical media, accessible on multiple devices.
Compatibility:
Compatible with all versions of Windows and Mac, requires Adobe PDF Reader.
📋 Manual Details
Coverage Areas
Coverage Overview:
Comprehensive service and repair for specified Kawasaki KX125 and KX250 models.
Page Count
Page Count:
Not specified in product information, but described as 'most complete'.
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Fuel System, Cooling System, Engine Top End, Engine Right Side, Engine Removal/Installation, Engine Bottom End/Transmission
Chassis Systems:
Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame
Electrical Systems:
Electrical System
Procedures Included
Repair Procedures:
Assembling, Disassembling, Troubleshooting, Repair
Maintenance Procedures:
General maintenance and service procedures
Diagnostic Procedures:
Implied through detailed repair and troubleshooting sections
Technical Depth
Depth Of Information:
Comprehensive, covering all necessary aspects for service and repair, including wiring diagrams.
Appendices
Appendix Content:
Likely includes technical specifications, torque values, troubleshooting charts, wiring diagrams, and potentially special tool requirements.
📊 Manual Specifications
File Format
File Format Details:
High Quality PDF, all pages printable, searchable text implied.
Print Quality
Print Quality:
High Quality PDF, ensuring clear reproduction when printed.
Binding Type
Binding Type:
Digital download, no physical binding.
Paper Type
Paper Type:
Not applicable for digital download, printable on user's choice of paper.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, liquid-cooled (specific displacement varies by model).
Kx125 Displacement:
124cc (approximate, specific bore/stroke would be detailed in manual)
Kx250 Displacement:
249cc (approximate, specific bore/stroke would be detailed in manual)
Performance
Power Delivery:
High-revving, aggressive powerbands characteristic of motocross competition bikes. Detailed power and torque curves would be in the manual.
Fuel System
Carburetor Type:
Typically a Keihin PWK (e.g., PWK38 for KX250, PWK36 for KX125), with detailed jetting and adjustment procedures in the manual.
Fuel Type:
Premium unleaded gasoline, 91 octane or higher recommended. Pre-mix oil ratio for two-stroke oil specified in manual.
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed sequential manual transmission.
Optional
Transmission Options:
N/A (standard feature).
Features
Transmission Features:
Heavy-duty components for motocross use. Specific gear ratios and clutch service details are covered.
Fluid Specifications
Transmission Oil Type:
Specific SAE 10W-30 or 10W-40 API SG or SH transmission oil. Capacity details in manual.
📐 Dimensions
Exterior
Overall Length:
Varies by year and model, precise figures available in manual.
Overall Width:
Varies by year and model, precise figures available in manual.
Overall Height:
Varies by year and model, precise figures available in manual.
Weights
Dry Weight:
Approx. 91-93 kg (200-205 lbs) for KX125, Approx. 96-98 kg (212-216 lbs) for KX250. Exact figures per model year in manual.
Curb Weight:
Not typically advertised for competition dirt bikes, manual will provide operating weight with fluids.
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable (off-road competition vehicles).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Manual covers maintenance, fluid types (DOT 4), and bleeding procedures.
Passive Features
Frame Construction:
Perimeter frame, typically aluminum alloy, designed for rigidity and handling. Manual details frame inspection and potential repairs.
💡 Technology Features
Infotainment
Infotainment Systems:
N/A (off-road competition motorcycle).
Driver Assistance
Assistance Features:
N/A (off-road competition motorcycle).
Connectivity
Connectivity Features:
N/A (off-road competition motorcycle).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended at specified hours or mileage, detailed in manual. Regular transmission oil changes are critical for two-stroke performance.
Engine Top End Rebuild:
Intervals vary based on usage (e.g., hours of riding, race vs. trail). Manual will provide guidance on piston ring and cylinder wear limits.
Fluid Specifications
Coolant Type:
Proprietary or standard ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Specifics in manual.
Fork Oil Type:
Specific fork oil viscosity (e.g., Showa SS-05, KYB 01F, or equivalent SAE 5W or 7.5W). Manual will specify type and volume per fork leg.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Clutch plates, brake pads, wheel bearings, steering bearings, suspension seals, piston rings, reeds. Manual will detail inspection and replacement procedures.
Kx250 Power Valve Issues:
The automatic KIPS (Kawasaki Integrated Power Valve System) can be a source of performance issues if carbon buildup occurs or mechanisms wear. Manual provides detailed cleaning and adjustment procedures.
Cooling System Maintenance:
Regular flushing and inspection of hoses and radiator for leaks or blockages is crucial for preventing overheating, especially in demanding conditions. Manual details this process.
📚 Vehicle History
Brand Heritage
Kawasaki Motocross Legacy:
Kawasaki has a long and successful history in motocross racing, with the KX line being a cornerstone of their off-road performance.
Model Evolution
Kx125 Evolution 03-08:
This generation saw significant updates, including revised chassis geometry, suspension tuning, and engine refinements aimed at improving competitiveness in the highly contested 125cc class. The 2003 model introduced a significant chassis update.
Kx250 Evolution 03-08:
The KX250 in this era received updates to its powerful two-stroke engine, suspension, and chassis. Note: Kawasaki introduced a 250F four-stroke model during this period, so this manual specifically covers the 250cc two-stroke variants.
Production
Manufacturing Location:
Typically manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Motocross Magazine Reviews:
Models in this era consistently received praise and awards from motocross publications for their performance, handling, and suspension capabilities. Manual helps maintain this peak performance.
Ratings
Performance Ratings:
High performance for their class, competing directly with Yamaha YZ, Honda CR, and Suzuki RM models. Manual is essential for owners to keep them competitive.
Certifications
Emissions Certifications:
N/A (off-road competition vehicles are typically not subject to road-going emissions standards).
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