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Kawasaki KX125/KX250 (1999 to 2002) Service Repair Manual

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This manual covers the motocross competition motorcycles manufactured between 1999 and 2002. These models, identified by chassis codes KX125-K1, KX125-K2, KX125-K3 for the 125cc and KX250-K1, KX250-K2, KX250-K3 for the...
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Type: Motorcycle
Vendor:
Sku: 131656
Kawasaki KX125/KX250 (1999 to 2002) Service Repair Manual
This manual covers the motocross competition motorcycles manufactured between 1999 and 2002. These models, identified by chassis codes KX125-K1, KX125-K2, KX125-K3 for the 125cc and KX250-K1, KX250-K2, KX250-K3 for the 250cc, represent a significant era in motocross technology. They are engineered for peak performance on the track, featuring liquid-cooled, two-stroke engines with an Integrated Power Valve System for enhanced power delivery across the rev range. The KX series is renowned for its competitive edge, strong heritage in racing, and robust construction designed to withstand the rigors of off-road competition, making them a popular choice for enthusiasts and professional racers alike. This comprehensive Service Repair Manual provides detailed information essential for the maintenance, troubleshooting, and repair of your KX125 or KX250. It covers a complete range of procedures, from routine maintenance tasks such as oil changes and filter cleaning to in-depth engine and chassis overhauls. The manual includes extensive guidance on all major systems, including the engine, fuel system, transmission, suspension, brakes, and electrical components, supported by numerous diagrams and illustrations. With this resource, owners and technicians can confidently perform all necessary work to keep these high-performance machines in optimal condition, ensuring reliability and peak performance on and off the track.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX125/KX250
Covered Years:
1999, 2000, 2001, 2002
Codes
Chassis Codes Kx125:
KX125-K1, KX125-K2, KX125-K3
Chassis Codes Kx250:
KX250-K1, KX250-K2, KX250-K3
👋 Introduction
Market Position
Vehicle Segment:
Motocross Competition
Target Audience:
Enthusiasts, mechanics, owners of 1999-2002 Kawasaki KX125 and KX250 models
Competitive Analysis
Key Competitors:
Honda CR125R/CR250R, Yamaha YZ125/YZ250, Suzuki RM125/RM250, KTM 125/250 SX
Key Features
Manual Value Proposition:
Essential resource for maintaining and repairing these performance-oriented motocross bikes, covering all aspects of the vehicle
Repair Focus:
Enables owners to perform DIY repairs and maintenance, saving on labor costs and ensuring proper upkeep.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual / Workshop Manual
Scope:
Complete tear down and rebuild, maintenance, troubleshooting, repair
Page Count
Total Pages:
260
Language
Language:
English
Format
Digital Format:
PDF (Adobe Acrobat)
Compatibility:
Windows and Mac OS
📖 Manual Coverage
Systems Covered
Engine Internal:
Cylinder, piston, crankshaft, connecting rod, bearings, seals, cylinder head, power valve system
Fuel System:
Carburetor (cleaning, adjustment, jetting), fuel lines, fuel tank
Ignition System:
CDI unit, ignition coil, spark plug, stator, flywheel
Cooling System:
Radiator, coolant hoses, water pump
Exhaust System:
Exhaust pipe, muffler
Transmission:
Clutch (operation, adjustment, replacement), gearbox, shift drum, shift forks, gears, bearings
Drivetrain:
Chain and sprockets (inspection, replacement)
Suspension Front:
Front fork (disassembly, assembly, oil change, seal replacement, spring replacement, damping adjustment), steering head bearings
Suspension Rear:
Monoshock rear suspension, linkage system, swingarm, rear shock absorber (rebuild, adjustment), bearings
Brakes Front:
Brake caliper, master cylinder, brake pads, brake disc, brake lines
Brakes Rear:
Brake caliper, master cylinder, brake pads, brake disc, brake lines
Wheels Tires:
Spoke inspection and tensioning, wheel bearings, tire replacement
Electrical System:
Lighting circuits (if applicable), wiring diagrams, fuses, battery (if electric start model)
Frame Bodywork:
Frame inspection, fuel tank, seat, fenders, plastics, radiator shrouds
Procedures Included
Maintenance Routine:
Oil changes, filter cleaning/replacement, chain adjustment, spark plug inspection, air filter cleaning/replacement
Troubleshooting:
Diagnostic guides for common problems, electrical system troubleshooting
Repair Rebuild:
Complete engine disassembly and reassembly, gearbox overhaul, suspension servicing, brake system overhaul
Adjustments:
Carburetor tuning, clutch lever free play, brake lever free play, suspension settings
Technical Depth
Depth Level:
Comprehensive, covering basic maintenance to full engine and chassis rebuilds
Data Availability:
Detailed torque specifications, clearances, fluid capacities, and diagnostic procedures
Visual Aids
Illustrations:
Numerous pictures and diagrams for visual guidance
📊 Manual Specifications
File Format
File Type:
Adobe PDF
Searchability:
Searchable text content within the PDF
Print Quality
Printability:
Fully printable pages
Binding Type
Digital Binding:
N/A (Digital format)
Paper Type
Digital Paper Equivalent:
High-resolution digital document
⚙️ Engine Specifications
Primary Engine Kx125
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
123.7 cc
Bore X Stroke:
54.0 mm x 54.5 mm
Compression Ratio:
8.5:1 (typical, may vary)
Power Valve:
Kawasaki Integrated Power Valve System (KIPS)
Carburetor:
Mikuni VM26SS (typical)
Primary Engine Kx250
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
249 cc
Bore X Stroke:
66.4 mm x 72.0 mm
Compression Ratio:
7.8:1 (typical, may vary)
Power Valve:
Kawasaki Integrated Power Valve System (KIPS)
Carburetor:
Keihin PWK38 (typical)
Performance
Horsepower Kx125 Approx:
37-39 HP (at crank, model year dependent)
Horsepower Kx250 Approx:
45-48 HP (at crank, model year dependent)
Fuel System
Fuel Type:
Unleaded gasoline with 2-stroke oil mix (premix or injection system)
Oil Type Premix:
High-quality 2-stroke motorcycle oil (refer to manual for specific API/JASO ratings)
🔧 Transmission
Standard
Transmission Type:
Constant-mesh, 6-speed sequential
Optional
Transmission Options:
N/A (standard 6-speed gearbox)
Features
Clutch Type:
Wet, multiple-disc
📐 Dimensions
Exterior Kx125 Approx
Length:
2140 mm (84.3 in)
Width:
820 mm (32.3 in)
Height:
1220 mm (48.0 in)
Wheelbase:
1450 mm (57.1 in)
Weights Kx125 Approx
Dry Weight:
93 kg (205 lbs)
Exterior Kx250 Approx
Length:
2160 mm (85.0 in)
Width:
820 mm (32.3 in)
Height:
1230 mm (48.4 in)
Wheelbase:
1455 mm (57.3 in)
Weights Kx250 Approx
Dry Weight:
99 kg (218 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Competition off-road vehicles typically do not undergo standardized crash testing or receive NHTSA/Euro NCAP ratings)
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Passive Features
Chassis Construction:
Strong steel perimeter frame designed for motocross abuse.
💡 Technology Features
Infotainment
Infotainment Features:
N/A (Motocross bikes are performance-focused and lack infotainment systems.)
Driver Assistance
Assistance Features:
N/A (No electronic driver assistance features present.)
Connectivity
Connectivity Options:
N/A (No electronic connectivity features.)
🔧 Maintenance
Service Intervals
Oil Change Engine:
Every 5-10 hours of riding or as specified by manual (depending on severity of use).
Air Filter Cleaning:
After every few rides or more frequently in dusty conditions.
Spark Plug Inspection:
Every 10-20 hours of riding.
Chain Lubrication:
Every ride, or as needed.
Fluid Specifications
Transmission Oil Type:
API GL-4 SAE 80 or 10W-30 motorcycle transmission oil (check manual for specific viscosity and brand recommendations).
Coolant Type:
Permanent type antifreeze coolant (50% mixture with distilled water)
Fork Oil Type Kx125:
SAE 0W-20 or SAE 10W (check manual for specific viscosity and quantity per fork leg).
Fork Oil Type Kx250:
SAE 5W or SAE 10W (check manual for specific viscosity and quantity per fork leg).
Known Issues
Common Wear Items:
Piston rings, top end (cylinder, piston), clutch plates, wheel bearings, steering head bearings, suspension seals.
Potential Failures:
Power valve system malfunctions if not properly maintained, crankcase seals, clutch slave cylinder leaks.
Maintenance Philosophy
Importance Of Premix:
Crucial for two-stroke engine longevity; using the correct oil and ratio is vital.
📚 Vehicle History
Brand Heritage
Kawasaki Offroad Legacy:
Kawasaki has a long and successful history in motocross racing, with the KX line being a dominant force.
Model Evolution Kx125
Kx125 Development Era:
The 1999-2002 era saw significant advancements in motocross technology, including improved suspension, chassis rigidity, and engine performance with advanced power valve systems.
Model Evolution Kx250
Kx250 Development Era:
The KX250 also benefited from the continuous development, offering a powerful and competitive package for motocross and Supercross racing.
Production
Manufacturing Location:
Japan (typically)
🏆 Awards & Recognition
Recognitions
Racing Success:
Kawasaki KX models, including these years, have achieved significant success in professional motocross and Supercross championships globally.
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