2003-2007 Kawasaki KX125 KX250 2-Stroke Motorcycle Repair

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UGS: 149947

Mots clés: 2003 2004 2005 2006 2007 4 Stroke Engines Manuals Engines Kawasaki KX125 KX250 Motorcycle

Variantes de produits

Description

This manual covers the motocross motorcycles produced between 2003 and 2007. These 2-stroke competition models are renowned for their performance-oriented engineering, delivering potent power and agile handling crucial for the demanding sport of motocross. The KX line boasts a rich heritage in racing, with these particular model years featuring advancements in engine technology, suspension, and chassis design aimed at providing riders with a competitive edge. Their robust construction and focus on rider feedback have made them popular choices for enthusiasts and professional racers alike. This comprehensive English-language repair and workshop manual provides detailed information essential for the maintenance, repair, and troubleshooting of your motocross motorcycle. It covers all major systems, including the engine, drivetrain, chassis, and electrical components, with step-by-step procedures, technical specifications, torque values, and diagnostic flowcharts. Whether you are performing routine maintenance, addressing specific issues, or undertaking a complete rebuild, this manual serves as an invaluable resource for owners and technicians, ensuring your motorcycle remains in optimal condition and performance.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Generation

Years Covered:

2003, 2004, 2005, 2006, 2007

Codes

Engine Type:

2-Stroke

👋 Introduction

Market Position

Target Audience:

Enthusiasts, DIY mechanics, professional technicians working on Kawasaki KX125 and KX250 motocross motorcycles

Competitive Analysis

Benefit:

Provides essential information for maintenance and repair, reducing reliance on costly dealer services or incomplete online resources.

Key Features

Accessibility:

Instant download after payment, accessible on various devices like smartphones, tablets, and computers.

Durability:

Lifetime protection policy against loss or damage.

Environmental:

Eco-friendly digital format, saving paper resources.

📋 Manual Details

Coverage Areas

Manual Type:

Repair Manual / Workshop Manual

Language:

English

Format:

PDF Download

Content Scope:

Comprehensive Repair, Maintenance, Troubleshooting, and Parts Information

📖 Manual Coverage

Systems Covered

Engine:

Engine Removal and Installation, Engine Specifications, Lubrication and Cooling System, Intake & Exhaust, Fuel System

Drivetrain:

Transmission, Drive Chain & Sprockets

Chassis:

Steering System, Shocks, Body Work

Electrical:

Electrical System

Procedures Included

Maintenance:

Routine Maintenance, Scheduled Servicing

Repair:

Component Repair and Rebuild Procedures

Troubleshooting:

Advanced Troubleshooting Guides, Diagnostic Procedures

Technical Depth

Depth:

Detailed repair procedures, torque specifications, clearances, and diagnostic flowcharts

📊 Manual Specifications

File Format

Type:

Searchability:

Searchable text for quick information retrieval

Print Quality

Quality:

High-resolution for clear diagrams and text

Binding Type

Type:

Digital Download (No physical binding)

Paper Type

Type:

Not Applicable (Digital)

⚙️ Engine Specifications

Primary Engine

Type:

Liquid-cooled, 2-stroke single cylinder

Kx125 Displacement:

124 cc

Kx250 Displacement:

249 cc

Kx125 Bore X Stroke:

54.0 x 54.5 mm

Kx250 Bore X Stroke:

66.4 x 72.0 mm

Performance

Kx125 Approx Hp:

~35-40 hp (at crank, dependent on tuning)

Kx250 Approx Hp:

~45-50 hp (at crank, dependent on tuning)

Fuel System

Carburetor Kx125:

Keihin PWK38

Carburetor Kx250:

Keihin PWK39

Fuel Type:

Unleaded Gasoline (minimum 91 octane recommended) with 2-stroke oil mix

Oil Mix Ratio:

50:1 (Kawasaki recommends their specific 2-stroke oil)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch:

Wet multi-disc, cable operated

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Kx125 Length:

Approx. 85.8 in (2179 mm)

Kx250 Length:

Approx. 86.0 in (2185 mm)

Kx125 Width:

Approx. 31.7 in (805 mm)

Kx250 Width:

Approx. 31.7 in (805 mm)

Kx125 Height:

Approx. 48.6 in (1235 mm)

Kx250 Height:

Approx. 48.6 in (1235 mm)

Weights

Kx125 Dry Weight:

Approx. 205.1 lb (93 kg)

Kx250 Dry Weight:

Approx. 222.7 lb (101 kg)

Fuel Tank Capacity:

Approx. 2.1 gal (8.0 L)

Kx125 Wheelbase:

Approx. 57.7 in (1465 mm)

Kx250 Wheelbase:

Approx. 57.7 in (1465 mm)

🛡️ Safety Features

Ratings

Type:

Off-road motorcycles do not typically receive NHTSA or Euro NCAP safety ratings.

Active Features

Braking Front:

Hydraulic disc brake

Braking Rear:

Hydraulic disc brake

Passive Features

Frame:

Perimeter frame (steel)

💡 Technology Features

Infotainment

Features:

Not applicable for competition motocross motorcycles.

Driver Assistance

Features:

Not applicable for competition motocross motorcycles.

🔧 Maintenance

Service Intervals

Air Filter Cleaning:

Check and clean after every few rides or as needed based on conditions.

Spark Plug Inspection:

Inspect and clean/replace every 10-15 hours of use or as per manual recommendations.

Chain Lubrication Adjustment:

Lubricate and check tension before every ride.

Top End Rebuild:

Recommended every 30-50 hours of heavy use, depending on riding style and maintenance.

Fluid Specifications

Engine Oil:

Kawasaki KART 2-Stroke Oil or equivalent (JASO FD Certified)

Transmission Oil:

SAE 10W-40 API SG or higher, KAWASAKI GEAR OIL (part no. 92140-1052) or equivalent

Coolant:

High-quality ethylene glycol based antifreeze mixed with distilled water (50/50 ratio)

Known Issues

Kx125 Power Band:

Known for a potent but narrow powerband, requiring precise clutch and gear work.

Kx250 Power Band:

Offers a broader, more tractable power delivery than the 125, but still requires attention to jetting and engine condition.

Suspension Setup:

Proper suspension tuning is crucial for optimal performance and rider comfort on both models.

Clutch Wear:

Clutch plates can wear relatively quickly with aggressive riding; regular inspection and replacement are advised.

📚 Vehicle History

Brand Heritage

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Model Evolution

Kx Line:

The KX line has a long-standing reputation in motocross racing, evolving significantly throughout the years with advancements in engine technology, suspension, and chassis design.

Kx125 2003:

The 2003 model saw significant revisions, often including a revised cylinder design, reed valve system, and chassis geometry for improved power delivery and handling.

Kx250 2003:

The 2003 KX250 also received updates, focusing on powerband refinement, suspension performance, and chassis rigidity, continuing Kawasaki's push in the 250cc motocross class.

Production

Segment:

Motocross Competition Motorcycle

🏆 Awards & Recognition

Recognitions

Racing Success:

The KX line has a strong history of success in professional motocross and supercross racing championships.

Ratings

Editorial Reviews:

Period reviews from motorcycle publications of the era generally praised the KX models for their potent engines, capable suspension, and competitive chassis.