Systems Covered Overview:
General Information, 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
Estimated Page Count:
Detailed (Exact count not specified, but typical for comprehensive service manuals)
Type:
Service Repair Manual
Engine Top End:
Cylinder, cylinder head, piston, piston rings, connecting rod, camshafts (if applicable), valves, valve springs, valve guides, valve seats, timing chain/gears, cylinder head gasket.
Engine Right Side:
Crankcase cover, ignition system components (stator, flywheel, ignition coil), clutch assembly, water pump assembly, kick starter mechanism.
Engine Removal Installation:
Step-by-step procedures for safely removing the engine from the chassis and reinstalling it, including necessary connections and mounts.
Engine Bottom End Transmission:
Crankshaft, bearings, seals, transmission gears, shift drum, shift forks, clutch components, transmission bearings, seals, oil seals.
Fuel System:
Carburetor(s) disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, fuel filter, fuel pump (if applicable).
Cooling System:
Radiator, coolant hoses, thermostat, water pump, coolant type and capacity, bleeding procedures.
Wheels Tires:
Wheel bearing replacement, spoke tensioning, tire mounting/dismounting, tube replacement, rim maintenance, wheel balancing.
Final Drive:
Chain maintenance, sprocket replacement, chain lubrication, chain tension adjustment, gear oil specifications and replacement.
Brakes:
Brake fluid type and capacity, brake pad replacement, caliper maintenance, master cylinder service, brake line inspection and replacement, bleeding procedures, rotor inspection and replacement.
Suspension:
Front fork service (oil change, seal replacement, spring inspection), rear shock absorber maintenance, linkage service, bushing replacement, suspension settings.
Steering:
Steering head bearing inspection and replacement, handlebar maintenance, linkage lubrication and adjustment.
Electrical System:
Wiring diagrams, lighting systems, ignition system troubleshooting, battery maintenance, fuse identification and replacement, charging system components.
Maintenance:
Routine maintenance tasks, lubrication points and schedules, filter replacement, fluid changes, general inspection procedures.
Diagnostics:
Troubleshooting guides for common problems, diagnostic steps for engine performance issues, electrical system faults, and other operational anomalies.
Repair:
Detailed, step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Rebuilds:
Comprehensive rebuild procedures for major components like the engine, transmission, and suspension.
Specifications Torque:
Critical torque specifications for fasteners, bolts, and nuts throughout the vehicle.
Depth:
Comprehensive - intended for dealership technicians, covering all aspects from basic maintenance to advanced diagnostics and complete overhauls.
Kx125 Engine Type:
Liquid-cooled, 2-stroke, single cylinder
Kx250 Engine Type:
Liquid-cooled, 2-stroke, single cylinder
Kx125 Bore X Stroke:
52.5 x 57.5 mm (approximate for the era)
Kx250 Bore X Stroke:
66.4 x 72.0 mm (approximate for the era)
Kx125 Power Output:
Approximately 35-40 HP (varies by year and specific tuning)
Kx250 Power Output:
Approximately 45-50 HP (varies by year and specific tuning)
Carburetion Type:
Mikuni VM series (typical for the era, specific model numbers covered in manual)
Fuel Type:
Unleaded gasoline with proper 2-stroke oil pre-mix (ratio specified in manual)
Reed Valve System:
Covered for performance and maintenance.
Oil Change Transmission:
Recommended every 10-15 hours of riding or annually. Specific interval in manual.
Air Filter Cleaning:
As needed, depending on riding conditions (frequently in dusty environments).
Spark Plug Replacement:
Recommended based on hours or visual inspection for wear and fouling.
Top End Rebuild:
Recommended based on hours of use (e.g., 20-40 hours for piston/rings, 40-60 hours for cylinder/crankshaft bearings).
Engine Oil Type:
2-stroke premix oil (specific API/JASO ratings detailed in manual)
Transmission Oil Type:
Hypoid gear oil SAE 80 or SAE 10W-30 (specific type and API classification in manual)
Coolant Type:
Ethylene glycol-based antifreeze coolant (specific type and mixture ratio in manual)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (specific type in manual)
Power Valve Sticking:
Common on 2-stroke engines of this era due to carbon buildup; manual covers cleaning and adjustment.
Clutch Wear:
Clutch plates and springs can wear over time; manual details inspection and replacement.
Suspension Seals:
Fork seals and shock seals can degrade and leak; manual provides replacement procedures.
