Positioning:
The Kawasaki KX series of the late 90s and early 2000s were highly regarded motocross and off-road racing machines, known for their potent two-stroke engines and competitive chassis. This manual is aimed at owners and technicians needing to maintain and repair these performance-oriented motorcycles.
Competitors:
Competes directly with service manuals for Yamaha YZ series, Honda CR series, and Suzuki RM series of the same period. Known for robust engine performance and a direct, engaging riding feel.
Manual Highlights:
Extensive coverage of the two-stroke engines, detailed wiring diagrams, and comprehensive suspension adjustment procedures specific to motocross applications.
Major Sections:
General Information, Periodic Maintenance, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Estimated Page Count:
Approximately 400-600 pages (typical for comprehensive service manuals of this era)
Type:
Workshop Service Repair Manual
Format:
Digital (PDF) - Searchable and Printable
Powertrain:
Engine Top End (cylinder, piston, rings, head), Clutch (operation, adjustments, components), Engine Lubrication System (oil pump, passages), Crankshaft/Transmission (gearbox, shifting mechanism, bearings), Fuel System (carburetor, fuel lines, petcock), Cooling System (radiator, hoses, coolant)
Chassis:
Wheels/Tires (rims, spokes, tire mounting, balancing), Final Drive (chain, sprockets), Brakes (hydraulic systems, pads, discs, calipers), Suspension (front forks, rear shock, linkages, adjustments), Steering (headset, handlebars, controls)
Electrical:
Ignition system, lighting, charging system, wiring diagrams, troubleshooting electrical faults
Routine Maintenance:
Oil changes, filter replacement, spark plug service, air filter cleaning/replacement, chain adjustment, brake pad inspection, tire pressure checks, coolant level checks, valve clearance (if applicable to the specific engine design of this era).
Repair And Rebuild:
Engine disassembly/assembly, carburetor tuning and rebuilding, clutch component replacement, transmission gear inspection and replacement, brake system bleeding and component replacement, suspension fork seal replacement, wheel bearing replacement, steering head bearing service.
Troubleshooting:
Diagnostic procedures for common running issues, electrical faults, and mechanical failures. Includes symptom-based troubleshooting guides.
Depth:
Comprehensive, covering everything from basic adjustments and fluid changes to complete engine and transmission rebuilds. Detailed specifications, torque values, and diagnostic procedures are included.
Type:
Two-stroke, liquid-cooled, single-cylinder
Displacement Kx125:
124 cc (approx.)
Displacement Kx250:
249 cc (approx.)
Bore Stroke Kx125:
Varies by specific year, typically around 54.0 mm x 54.5 mm
Bore Stroke Kx250:
Varies by specific year, typically around 66.4 mm x 72.0 mm
Power Delivery:
Aggressive powerband characteristic of performance two-strokes. Specific horsepower figures are not provided here but are documented in the manual.
Carburetor Kx125:
Typically Keihin PWK Series (e.g., 35mm or 38mm)
Carburetor Kx250:
Typically Keihin PWK Series (e.g., 38mm or 39mm)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Premix:
Requires 2-stroke oil premixed with gasoline at a specified ratio (e.g., 40:1 or 50:1, check manual for exact specification)
Features:
N/A (Competition motocross motorcycles).
Features:
N/A (Competition motocross motorcycles).
Features:
N/A (Competition motocross motorcycles).
Kips System:
Kawasaki Integrated Power Valve System (KIPS) - Variable exhaust port timing system to optimize power delivery across the RPM range. The manual details its operation, maintenance, and adjustment.
Oil Change:
Every 8-15 hours of riding, or as specified in the manual for specific conditions.
Air Filter:
Clean or replace every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug:
Inspect and clean/replace as needed, typically every 20-30 hours of riding.
Top End Rebuild:
Recommended every 40-60 hours of riding for optimal performance, depending on usage and maintenance.
Engine Oil:
Not applicable (2-stroke oil is premixed with fuel). Transmission oil specified separately.
Coolant:
Mixture of distilled water and antifreeze (ethylene glycol based) with anti-corrosion additives. Specific type and ratio detailed in manual.
Brake Fluid:
DOT 4 hydraulic brake fluid
Common Wear Items:
Piston rings, clutch plates, spark plugs, chain and sprockets, fork seals, wheel bearings, and suspension linkages are common wear items due to the demanding nature of motocross.
Carburetor Fouling:
Carburetors can be susceptible to clogging from fuel deposits or dirt ingress if not properly maintained. Regular cleaning and proper air filter maintenance are crucial.
Power Valve System:
The KIPS system (Kawasaki Integrated Power Valve System) requires periodic inspection and cleaning of the carbon buildup to ensure optimal performance.
Suspension Maintenance:
Fork seals and bushings wear over time, requiring replacement to prevent oil leaks. Rear shock linkages and bearings need periodic greasing and inspection.
Kawasaki Motocross:
Kawasaki has a long and successful history in motocross racing, with the KX line consistently being a competitive force.
Kx Line Evolution:
The KX125 and KX250 models underwent continuous development, incorporating advancements in suspension, engine technology (like KIPS - Kawasaki Integrated Power Valve System), and chassis design throughout the 1990s and early 2000s.
Production Period:
The KX125 and KX250 were produced for many years, with the 1999-2002 generation representing a specific technological iteration.
