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2003-2004 Kawasaki KX125 KX250 KX125-M1 M2 KX250-M1 M2 models Service Repair Manual

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This manual provides comprehensive service and repair information for the KX125 and KX250 models, covering production years 2003 and 2004. These motorcycles are renowned for their performance and competitive edge...
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Taper: Motorcycle
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UGS: 149974
2003-2004 Kawasaki KX125 KX250 KX125-M1 M2 KX250-M1 M2 models Service Repair Manual
This manual provides comprehensive service and repair information for the KX125 and KX250 models, covering production years 2003 and 2004. These motorcycles are renowned for their performance and competitive edge in motocross, building on a rich motorsports heritage. The KX line has consistently been developed for optimal performance, making these machines highly regarded in their respective classes. This guide is designed to assist owners and mechanics in maintaining these powerful off-road competition motorcycles. The scope of this Service Repair Manual is extensive, detailing all essential aspects of the vehicle. It includes in-depth coverage of engine systems, drivetrain, chassis components, and the electrical system. Within these sections, you will find detailed step-by-step instructions for maintenance, repair, and diagnostic procedures, supported by numerous diagrams, illustrations, and photos. The manual also provides critical technical specifications, torque values, and component clearances necessary for accurate servicing. Its user-friendly format, featuring clickable menus and search functionality, ensures efficient navigation and access to the information needed to keep your KX125 or KX250 in peak condition.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX125 / KX250
Model Codes:
KX125-M1, KX125-M2, KX250-M1, KX250-M2
Years Covered:
2003, 2004
Manual Product Number:
99924-1298-03
👋 Introduction
Market Position
Target Audience:
Do-it-yourself mechanics, owners seeking to save on dealer labor costs
Competitive Analysis
Value Proposition:
Cost-effective alternative to professional servicing, empowers owners with repair knowledge
Key Features
Delivery Method:
Instant Download, No Waiting
Cost Savings Potential:
Significant savings compared to dealer labor rates ($70+ per hour)
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for KX125 and KX250 models
Page Count
Page Count:
336 pages
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
General Information, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Crankcase
Drivetrain Systems:
Transmission, Final Drive
Chassis Systems:
Wheels/Tires, Brakes, Suspension, Steering, Frame
Electrical Systems:
Electrical System
Procedures Included
Maintenance Procedures:
Periodic Maintenance, Scheduled Servicing
Repair Procedures:
Engine Rebuild, Component Replacement, System Diagnostics
Diagnostic Procedures:
Troubleshooting, Fault Identification
Technical Depth
Technical Depth:
Detailed step-by-step instructions, diagnostic information, torque specifications, component clearances
Visual Aids
Illustrations:
Detailed diagrams, illustrations, photos, exploded views
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Print Capability:
Fully printable, high resolution
Binding Type
Recommended Binding:
3-ring binder (customer preference)
Paper Type
Paper Suitability:
Printable for garage use, disposable pages
Usability Features
Navigation:
Clickable menu, bookmarks, keyword searchable
Zoom Functionality:
Zoom in/out functionality for detailed views
⚙️ Engine Specifications
Primary Engine
Engine Type Kx125:
2-Stroke, Liquid-Cooled, Single Cylinder
Engine Type Kx250:
2-Stroke, Liquid-Cooled, Single Cylinder
Performance
Displacement Kx125:
124 cc (7.57 cu in)
Displacement Kx250:
249 cc (15.2 cu in)
Fuel System
Carburetor Kx125:
Keihin PJ34 (typical, exact spec in manual)
Carburetor Kx250:
Keihin PWK39 (typical, exact spec in manual)
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil premix (specific ratio in manual)
Ignition
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with variable timing (details in manual)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh sequential
Features
Clutch Type:
Wet multi-disc, manual
Fluid Specifications
Transmission Oil Type:
Kawasaki Gear Oil (specific grade and capacity detailed in manual)
📐 Dimensions
Exterior
Length:
Variable by model (refer to specific model sections in manual)
Width:
Variable by model (refer to specific model sections in manual)
Height:
Variable by model (refer to specific model sections in manual)
Weights
Dry Weight Kx125:
Approx. 93 kg (205 lbs) (verify in manual)
Dry Weight Kx250:
Approx. 99 kg (218 lbs) (verify in manual)
🛡️ Safety Features
Ratings
Safety Certification:
N/A for off-road competition motorcycles (manual focuses on mechanical safety)
Active Features
Braking System:
Hydraulic disc brakes front and rear (specifics on pads, fluid, bleeding in manual)
Passive Features
Frame Construction:
High-tensile steel perimeter frame (details on inspections and maintenance in manual)
💡 Technology Features
Infotainment
Infotainment System:
Not applicable to this off-road competition model.
Driver Assistance
Assistance Features:
Not applicable to this off-road competition model.
Connectivity
Connectivity Options:
Not applicable to this off-road competition model.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific intervals based on operating hours/conditions (engine oil for clutch/transmission)
Air Filter Cleaning:
Frequent cleaning/replacement recommended based on riding conditions (detailed procedures in manual)
Spark Plug Inspection:
Refer to manual for recommended inspection and replacement intervals
Fluid Specifications
Coolant Type:
High-quality motorcycle coolant with anti-freeze properties (specifics in manual)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (verify specific requirement in manual)
Known Issues
Common Wear Items:
Piston rings, clutch plates, brake pads, chain and sprockets (manual provides wear limits and replacement procedures)
Engine Top End Rebuild:
Regular top-end rebuilds (piston, rings, small end bearing) are critical for maintaining performance on 2-stroke engines (manual guides this process).
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki has a long and successful history in motocross and off-road racing with the KX line.
Model Evolution
Kx Line Development:
The KX125 and KX250 are renowned for their performance and competitiveness in their respective classes, with continuous refinements over the years.
Production
Manufacturing Region:
Japan (typical for Kawasaki performance models)
🏆 Awards & Recognition
Recognitions
Model Reputation:
The KX125 and KX250 have historically been highly regarded and competitive motocross machines, often winning races and championships.
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