This manual covers the motocross motorcycles from the 1999 to 2002 model years. These third-generation, liquid-cooled, 2-stroke machines, available in 124cc (KX125) and 249cc (KX250) displacements, represent a commitment to performance and off-road capability. Known for their potent engines and advanced chassis dynamics for their time, these models were designed for competitive motocross racing. The KX line boasts a strong heritage in off-road competition, with these specific generations receiving refinements aimed at enhancing handling and engine output to maintain their edge in the demanding 125cc and 250cc classes.
This comprehensive service and repair manual provides detailed guidance for owners, DIY mechanics, and professional technicians. It covers essential maintenance procedures, including routine service, fluid changes, and filter replacements, as well as in-depth repair instructions for all major systems. Key areas include engine systems, drivetrain, suspension, steering, electrical systems, and bodywork. The manual offers advanced troubleshooting steps, fault diagnosis, and component-level repair procedures, ensuring that users can effectively maintain, service, and repair their motorcycles to optimal performance standards.
Model Years Covered:
1999, 2000, 2001, 2002
Kx125 Generation:
Third Generation (KX125-J/K)
Kx250 Generation:
Third Generation (KX250-K/L)
Kx125 Model Codes:
KX125-K1, KX125-K2, KX125-K3
Kx250 Model Codes:
KX250-K1, KX250-K2, KX250-K3
Target Audience:
Owners, DIY mechanics, repair shops specializing in off-road motorcycles
Advantage Over Paper:
Instant download, easy access on mobile devices for trailside repairs, protection from grease and dirt, lifetime replacement policy
Accessibility:
Instant digital download after payment, no shipping delays
Usability:
Straightforward PDF format, optimized for quick navigation and printing of specific pages
Vendor Support:
Lifetime Protection Policy for lost or damaged files
Manual Type:
Repair, Service, Shop, Owner's Manual, Parts Catalog
Primary Coverage:
Repair, Service, Maintenance, Parts Lookup
Estimated Page Count:
Comprehensive (Specific count not provided, but implies full workshop manual coverage)
Document Type:
Downloadable PDF
File Format:
PDF (Plain, simple, easy to use, no zip files)
Engine Systems:
General Information, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Intake & Exhaust
Drivetrain Systems:
Transmission, Drive Chain & Sprockets
Suspension Steering:
Steering System, Shocks
Electrical Systems:
Electrical System
Bodywork Chassis:
Body Work
Maintenance Procedures:
Routine Maintenance, Service Intervals, Fluid Changes, Filter Replacements
Repair Procedures:
Engine Rebuilds, Transmission Overhaul, Suspension Servicing, Electrical Diagnosis and Repair
Troubleshooting:
Advanced Troubleshooting, Fault Diagnosis
Diagnostic Level:
Advanced Diagnostic Procedures, Fault Code Interpretation (if applicable)
Rebuild Scope:
Complete Engine Rebuild, Transmission Overhaul, Component-Level Repairs
Information Scope:
Detailed repair steps, torque specifications, wiring diagrams, component testing procedures
Readability:
High-resolution, clear text and diagrams for easy reading and printing
Digital Binding:
N/A (Digital Download)
Digital Paper Simulation:
Designed for on-screen use or printing on standard paper
Kx125 Engine Type:
Liquid-cooled, 2-stroke, reed-valve, single cylinder
Kx250 Engine Type:
Liquid-cooled, 2-stroke, reed-valve, single cylinder
Kx125 Displacement:
124 cc (7.57 cu in)
Kx250 Displacement:
249 cc (15.2 cu in)
Kx125 Bore X Stroke:
54.0 x 54.5 mm (2.13 x 2.15 in)
Kx250 Bore X Stroke:
67.4 x 72.0 mm (2.65 x 2.83 in)
Carburetor Kx125:
Keihin PJ38 (or similar)
Carburetor Kx250:
Keihin PJ39 (or similar)
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil pre-mix
Cooling Method:
Liquid-cooled
Kx125 Transmission Type:
6-speed, constant mesh, return shift
Kx250 Transmission Type:
6-speed, constant mesh, return shift
Clutch Type:
Wet, multi-disc
Overall Length:
Varies by model (refer to manual for specific dimensions)
Dry Weight Kx125:
Approx. 94 kg (207.2 lbs)
Dry Weight Kx250:
Approx. 101 kg (222.7 lbs)
Safety Certification:
Not applicable for off-road motorcycles in the same way as street vehicles; compliance with EPA emissions standards for off-highway vehicles.
Braking System:
Hydraulic disc brakes, front and rear
Frame Construction:
High-tensile steel perimeter frame
Infotainment Systems:
N/A (Off-road motorcycle, focused on performance, not infotainment)
Assistance Features:
N/A (Off-road motorcycle, no electronic rider aids like ABS or traction control)
Connectivity Options:
N/A
Oil Change Interval:
Refer to manual for specific transmission and engine oil change intervals based on riding hours.
Air Filter Cleaning:
Frequent cleaning and re-oiling of the air filter is critical for 2-stroke engine longevity, especially in dusty conditions.
Spark Plug Replacement:
Regular inspection and replacement as per manual recommendations or based on performance.
Engine Oil Type:
High-quality 10W-40 or 20W-50 motorcycle engine oil (specific viscosity depends on temperature). Refer to manual for precise recommendation.
Coolant Type:
Ethylene glycol-based coolant (50/50 mix with distilled water)
2 Stroke Oil Premix:
Specific 2-stroke racing oil recommended by Kawasaki. Pre-mix ratio (if applicable for oil injection system) as per manual.
Power Valve Maintenance:
Regular cleaning and inspection of the exhaust power valve mechanism is crucial for optimal engine performance and to prevent sticking.
Clutch Wear:
Clutch plates can wear over time, especially with aggressive riding. The manual provides inspection and replacement procedures.
Carburetor Tuning:
Proper jetting and tuning of the carburetor is essential for optimal performance and to prevent engine damage from lean conditions.
Suspension Seals:
Fork seals and shock seals can degrade over time, leading to leaks. Regular inspection is recommended.
Kawasaki Offroad Legacy:
Kawasaki has a long-standing reputation for performance-oriented motocross and off-road motorcycles, with the KX line being a dominant force.
Kx125 Evolution 99-02:
This generation saw continued refinement in suspension, engine performance, and chassis dynamics, aiming to improve handling and competitiveness in the 125cc class.
Kx250 Evolution 99-02:
The KX250 during these years focused on delivering strong engine power, improved suspension feedback, and more agile handling to compete in the highly competitive 250cc motocross segment.
Manufacturing Location:
Likely Japan or USA, consistent with Kawasaki's primary manufacturing hubs for this era.
Class Competitiveness:
The KX125 and KX250 models from this era were highly competitive in their respective classes during their production run, often receiving positive reviews from motocross publications for their performance and handling.
Industry Perception:
Regarded as capable and potent motocross machines for their time.
