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Kawasaki KX 125-250 (Kx 125 M1-3 Kx250 M1-2) Repair Manual

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This workshop repair manual provides comprehensive guidance for the Kawasaki KX125 and KX250 models, specifically those designated KX125 M1-M3 and KX250 M1-M2, likely from the mid to late 1980s. These...
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UGS: 136753
Kawasaki KX 125-250 (Kx 125 M1-3 Kx250 M1-2) Repair Manual
This workshop repair manual provides comprehensive guidance for the Kawasaki KX125 and KX250 models, specifically those designated KX125 M1-M3 and KX250 M1-M2, likely from the mid to late 1980s. These motorcycles represent a lineage of performance-oriented motocross machines, known for their aggressive, high-RPM power delivery characteristic of dedicated racing equipment. Engineered for demanding off-road use, they feature robust two-stroke engines, sophisticated suspension systems, and powerful hydraulic disc brakes. The Kawasaki KX line boasts a rich history of success in professional motocross and supercross, a testament to their enduring design and competitive spirit. This service manual serves as an essential resource for enthusiasts, DIY mechanics, and professional technicians. It covers a wide array of critical systems, including detailed procedures for general information, periodic maintenance, fuel and cooling systems, engine top and bottom end, transmission, wheels, final drive, brakes, suspension, steering, and the electrical system. With step-by-step instructions, exploded views, and diagrams, this manual facilitates efficient troubleshooting, maintenance, and repair, ensuring the longevity and optimal performance of your Kawasaki KX motorcycle. The digital format allows for immediate access and convenient printing for workshop use.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX125/KX250
Codes
Specific Model Codes:
KX125 M1-M3, KX250 M1-M2
Generation
Estimated Generation Years:
Mid to late 1980s (M1-M3, M1-M2 designations suggest this era)
👋 Introduction
Market Position
Target User:
Enthusiasts, DIY mechanics, and professional technicians working on Kawasaki KX125 and KX250 models of the specified generation.
Key Features
Manual Benefits:
Enables cost savings on repairs, extends motorcycle lifespan, provides in-depth understanding of vehicle systems, features detailed exploded pictures and diagrams.
Competitive Analysis
Advantage:
Instant download access eliminates shipping costs and wait times, offering immediate utility for urgent repair needs.
📋 Manual Details
Coverage Areas
Main Topics:
General Information, Periodic Maintenance, 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
Manual Type
Type:
Workshop Repair Manual / Service Manual
Language
Language:
English (assumed based on product description)
Format
Format:
Digital Download (PDF, printable)
📖 Manual Coverage
Systems Covered
Engine Systems:
Top End (cylinder, piston, head), Right Side Cover (clutch, ignition), Bottom End (crankshaft, connecting rod, bearings), Transmission (gearbox, shifting mechanism), Cooling System (radiator, water pump, hoses), Fuel System (carburetor, fuel lines, petcock)
Chassis Systems:
Wheels/Tires, Final Drive (chain, sprockets), Brakes (front and rear), Suspension (forks, rear shock, linkages), Steering (handlebars, triple clamps, bearings)
Electrical Systems:
Ignition system, lighting, charging system (if applicable), wiring diagrams
Procedures Included
Maintenance Procedures:
Periodic maintenance checks, lubrication, filter replacement, chain adjustment, brake fluid replacement
Repair Procedures:
Engine overhaul, carburetor tuning, suspension rebuild, wheel bearing replacement, brake caliper service, electrical troubleshooting and repair, transmission repair, engine removal and installation
Technical Depth
Depth:
Comprehensive workshop level, including exploded views, diagrams, step-by-step instructions for disassembly, assembly, adjustment, and troubleshooting.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Printability:
All pages are printable, ensuring physical copy creation for workshop use.
Binding Type
Binding Recommendation:
Digital format allows for custom binding (e.g., spiral-bound) for durability in a workshop environment.
Paper Type
Recommended Paper Type For Printing:
Standard paper for general use; heavier cardstock for cover pages and frequently referenced diagrams.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, liquid-cooled, single-cylinder (typical for KX models of this era)
Performance
Power Delivery:
Designed for aggressive, high-RPM power output characteristic of motocross racing machinery.
Fuel System
Carburetor Type:
Likely a performance-oriented Mikuni VM or TMX series carburetor, requiring precise tuning.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh sequential manual transmission
Features
Clutch Type:
Wet, multi-plate, cable-actuated clutch system
📐 Dimensions
Weights
Dry Weight Estimate Kx125:
Approximately 91-94 kg (200-207 lbs) for this era.
Dry Weight Estimate Kx250:
Approximately 98-102 kg (216-225 lbs) for this era.
🛡️ Safety Features
Active Features
Braking System:
Hydraulic disc brakes front and rear for enhanced stopping power and modulation.
Passive Features
Frame Construction:
Rigid steel perimeter frame providing stability and rider feedback.
💡 Technology Features
Infotainment
Infotainment Systems:
Not applicable. This is a performance motocross motorcycle, lacking modern infotainment features.
Driver Assistance
Rider Aids:
Not applicable. Focus is on raw performance and rider control; no electronic rider aids.
🔧 Maintenance
Service Intervals
Spark Plug Replacement:
Regular inspection and replacement based on riding conditions; typically every 10-20 hours of use for aggressive riding.
Air Filter Cleaning:
Mandatory after every few rides, especially in dusty conditions, to prevent engine damage.
Chain Lubrication And Adjustment:
Frequent lubrication (every ride or two) and adjustment to maintain proper tension (typically 1-1.5 inches of slack).
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.
Transmission Oil Type:
Dedicated motorcycle transmission oil or high-quality 10W-40 motorcycle engine oil (check manual for exact spec).
Known Issues
Two Stroke Wear:
Piston ring, piston, and cylinder wear are common due to the nature of two-stroke operation; regular top-end rebuilds are expected.
Carburetor Jetting:
Carburetor jetting may require adjustment for changes in altitude, temperature, or aftermarket exhaust/intake modifications.
Suspension Seals:
Fork seals and rear shock seals can degrade over time, leading to leaks and requiring replacement.
📚 Vehicle History
Brand Heritage
Kawasaki Motocross:
Kawasaki has a long and successful history in motocross racing, with the KX line being a dominant force for decades.
Model Evolution
Kx125 Kx250 Development:
These models represented significant advancements in motocross technology, evolving through chassis design, engine performance, and suspension technology.
🏆 Awards & Recognition
Recognitions
Motocross Legacy:
Kawasaki KX models have a storied history of success in professional motocross and supercross racing, earning numerous championships.
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