1992-1993 Kawasaki KX125 KX250 Motorcycle Workshop Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 141602

Tags: 1992 1993 Kawasaki KX Series KX125 KX250 Motorcycle Motorcycles

Product variants

Description

This manual covers the models from 1992 and 1993, identified by model codes KX125-J1, KX125-J2, KX250-J1, and KX250-J2. These motocross motorcycles, built in Japan, represent advancements in liquid-cooled, two-stroke engine technology and chassis design from their era. Kawasaki has a strong motorsports heritage, and these KX models were competitive in their class, known for their performance and handling, building upon the success of previous generations. This comprehensive workshop service repair manual in English provides in-depth information for service and repair. It covers essential systems including the engine, fuel system, cooling system, drivetrain, chassis, and electrical components. Detailed procedures for periodic maintenance, tune-ups, adjustments, diagnostics, troubleshooting, and component-level repairs, including full engine and transmission rebuilds, are included. The manual is designed to assist enthusiast DIYers, independent repair shops, and owners in maintaining and repairing their motorcycles, preserving their value and performance.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX125/KX250

Years Covered:

1992, 1993

Codes

Model Codes:

KX125-J1, KX125-J2, KX250-J1, KX250-J2

👋 Introduction

Market Position

Target Audience:

Enthusiast DIYers, Independent Repair Shops, and Owners seeking to maintain and repair their 1992-1993 Kawasaki KX125/KX250 motorcycles.

Competitive Analysis

Value Proposition:

Offers significant cost savings on dealership service fees by empowering owners with the knowledge to perform maintenance and repairs themselves. Crucial for preserving the value and performance of these vintage motocross machines.

Key Features

Benefits:

Instant Download, Printable Pages, High-Quality Diagrams, Comprehensive Coverage, Cost Savings.

📋 Manual Details

Coverage Areas

Primary Focus:

Service and Repair

Additional Sections:

General Information, Appendix

Page Count

Estimated Pages:

Comprehensive (Specific page count not provided, typical for this era workshop manuals is 300-600 pages)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Top End, Lubrication System, Crankshaft, Transmission

Fuel System:

Carburetor, Fuel Lines, Tank

Cooling System:

Radiator, Coolant, Hoses

Drivetrain:

Clutch, Final Drive, Chain, Sprockets

Chassis:

Wheels, Tires, Brakes (Front & Rear), Suspension (Front & Rear), Steering, Frame

Electrical:

Ignition System, Lighting, Wiring Diagrams

Procedures Included

Maintenance:

Periodic Maintenance, Tune-ups, Adjustments

Repair:

Engine Rebuilds, Transmission Overhaul, Suspension Servicing, Brake System Repair

Diagnostics:

Troubleshooting Guides, Fault Finding

Assembly Disassembly:

Engine Removal/Installation, Component Disassembly and Reassembly

Technical Depth

Depth:

Comprehensive: Covers routine maintenance, diagnostics, component-level repair, and full engine/transmission rebuilds. Includes detailed diagrams and specifications for accurate work.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Printable (High Quality Diagrams and Text)

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Quality:

Not Applicable (Digital Download)

Compatibility

Device Compatibility:

All Versions of Windows & Mac, APP ISO, iPhone, iPod, Android, and any device capable of opening PDF files.

Requirements

Software Requirements:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Kx125 Engine Type:

Liquid-cooled, 2-stroke, reed-valve, single-cylinder

Kx250 Engine Type:

Liquid-cooled, 2-stroke, reed-valve, single-cylinder

Performance

Kx125 Bore X Stroke:

56.0 x 50.6 mm

Kx250 Bore X Stroke:

66.0 x 72.0 mm

Kx125 Displacement:

124 cm³ (7.57 cu in)

Kx250 Displacement:

249 cm³ (15.2 cu in)

Kx125 Compression Ratio:

9.3:1 (Typical, check manual for exact spec)

Kx250 Compression Ratio:

9.1:1 (Typical, check manual for exact spec)

Fuel System

Carburetor Kx125:

Keihin PWK35 (Typical, check manual for exact spec)

Carburetor Kx250:

Keihin PWK38 (Typical, check manual for exact spec)

Fuel Type:

Unleaded gasoline with appropriate octane rating for 2-stroke engines (refer to manual for specific recommendations).

Fuel Oil Mixing:

Pre-mix (2-stroke oil mixed with gasoline, ratio specified in manual).

🔧 Transmission

Standard

Transmission Type Kx125:

6-speed constant mesh

Transmission Type Kx250:

6-speed constant mesh

Features

Clutch Type:

Wet, multi-disc

Gear Ratios:

Detailed gear ratios are provided within the manual for both models.

Final Drive:

Chain drive

📐 Dimensions

Weights

Kx125 Dry Weight:

Approx. 94 kg (207.2 lbs)

Kx250 Dry Weight:

Approx. 102 kg (224.9 lbs)

Fuel Tank Capacity Kx125:

8.0 L (2.1 US gal)

Fuel Tank Capacity Kx250:

8.0 L (2.1 US gal)

🛡️ Safety Features

Ratings

Safety Standards:

Not applicable for off-road motorcycles in the same manner as road vehicles; manual focuses on operational safety and component integrity.

Active Features

Braking System:

Hydraulic disc brakes, front and rear.

Passive Features

Frame Construction:

High-tensile steel perimeter frame (standard for motocross bikes of this era).

💡 Technology Features

Infotainment

Infotainment System:

Not applicable. This is a motocross motorcycle.

Driver Assistance

Assistance Features:

Not applicable. This is a motocross motorcycle.

Connectivity

Connectivity Features:

Not applicable. This is a motocross motorcycle.

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Refer to manual for specific recommendations based on riding conditions (e.g., after every few races for competition use).

Air Filter Cleaning:

Frequent cleaning and re-oiling required, especially in dusty conditions.

Spark Plug Replacement:

Recommended at specified intervals or as needed based on performance.

Fluid Specifications

Coolant Type:

High-quality, permanent type coolant (refer to manual for specific type and mixture ratio).

Fork Oil Type:

Specific viscosity fork oil (e.g., Showa SS-01, KYB 01, or equivalent as specified in manual).

Transmission Oil Type:

High-quality 2-stroke transmission oil (e.g., SAE 10W-30 API GL-4 or GL-5, check manual for exact spec).

Known Issues

Kx125 Common Wear Items:

Piston rings, clutch plates, crank seals, exhaust packing, swingarm bearings.

Kx250 Common Wear Items:

Piston, rings, clutch plates, crank seals, exhaust packing, swingarm bearings, power valve system components.

Carburetor Tuning:

Requires precise jetting and adjustment for optimal performance, especially with altitude or temperature changes. Power valve adjustment is critical on the KX250.

📚 Vehicle History

Brand Heritage

Kawasaki Motorsports:

Kawasaki has a long and storied history in motocross, with the KX line being a dominant force in competition for decades.

Model Evolution

Kx Series Development:

The early 90s KX models represented advancements in liquid cooling, chassis design, and suspension technology, building upon the success of previous generations.

Production

Manufacturing Location:

Japan (typical for Kawasaki motorcycles of this era)

🏆 Awards & Recognition

Recognitions

Motocross Reviews:

The KX series has consistently received positive reviews and numerous accolades in motocross publications for its performance and handling during its production years.

Ratings

Performance Benchmarks:

These models were competitive in their respective classes during the early 1990s motocross racing scene.