This manual covers the performance off-road motorcycles manufactured between 2003 and 2005. These models, including variations such as KX125-M1 through KX125-M3 and KX250-M1 through KX250-M2, represent a significant period in two-stroke motocross technology, known for their potent engines and competitive chassis. Building on a rich legacy in motocross racing, these motorcycles are engineered for demanding off-road use, featuring liquid-cooled, two-stroke single-cylinder engines, advanced suspension systems, and robust construction.
This comprehensive 340-page service repair manual provides detailed instructions for the maintenance, repair, and troubleshooting of your KX125 or KX250. It covers all essential aspects, including engine systems, fuel and cooling systems, chassis components, suspension, brakes, steering, and the electrical system with detailed wiring diagrams. The manual offers step-by-step procedures for disassembly, assembly, and repair, alongside periodic maintenance schedules, fluid specifications, and advanced diagnostic guidance. It is designed to assist owners, mechanics, and technicians in keeping these high-performance machines in optimal condition.
Model Codes Covered:
KX125-M1, KX250-M1, KX125-M2, KX250-M2, KX125-M3
Generation Years:
2003-2005
Manual Product Name:
2003-2005 Kawasaki KX125 KX250 Service Repair Manual Download
Vehicle Segment:
Performance Off-Road Motorcycle (Motocross)
Key Competitors:
Yamaha YZ125/YZ250, Honda CR125R/CR250R, Suzuki RM125/RM250, KTM 125 SX/250 SX
Manual Value Proposition:
Most complete service repair manual for the specified models, covering all essential aspects for maintenance and repair.
Digital Access:
Instant download eliminates shipping costs and wait times.
Primary Coverage:
Comprehensive service and repair for Kawasaki KX125 and KX250 models
Type:
Service Repair Manual
Compatibility:
All Versions of Windows & Mac
Required Software:
Adobe PDF Reader
Engine Systems:
General Information, Fuel System, Cooling System, Engine Top End, Engine Right Side, Engine Removal/Installation, Engine Bottom End/Transmission
Chassis Systems:
Wheels/Tires, Final Drive, Brakes, Suspension, Steering
Electrical Systems:
Electrical System, Wiring Diagrams
Appendix Content:
Likely includes specifications, torque values, special tools, and troubleshooting flowcharts.
Repair Procedures:
Assembling, Disassembling, Troubleshooting, Standard Repair Procedures
Maintenance Procedures:
Periodic Maintenance, Fluid Changes, Component Inspections
Wiring Diagrams Detail:
Comprehensive and clear wiring diagrams for electrical system troubleshooting and repairs.
Diagnostic Capability:
Advanced diagnostics and troubleshooting guidance
Rebuild Scope:
Detailed procedures for complete engine and component rebuilds
Frame And Bodywork:
Procedures for frame inspection, body panel removal/installation, and related components.
Digital Delivery:
Instant Download
Printability:
All pages are printable
Binding:
N/A (Digital PDF)
Paper Quality:
N/A (Digital PDF)
Engine Type Kx125:
Liquid-cooled, 2-stroke, single cylinder
Engine Type Kx250:
Liquid-cooled, 2-stroke, single cylinder
Bore Stroke Kx125:
54.0 x 54.5 mm (Approximate, manual will provide exact)
Bore Stroke Kx250:
66.4 x 72.0 mm (Approximate, manual will provide exact)
Displacement Kx125:
124 cc (Approximate, manual will provide exact)
Displacement Kx250:
249 cc (Approximate, manual will provide exact)
Cooling Method:
Liquid-cooled (Manual details radiator, hoses, and coolant flow)
Carburetor Kx125:
Keihin PWK38S (Typical, manual will confirm exact)
Carburetor Kx250:
Keihin PWK38SS (Typical, manual will confirm exact)
Fuel Type:
Unleaded gasoline (manual will specify octane rating and oil mix ratio)
Ignition System:
Digital CDI (manual will detail specific components and testing)
Clutch Type:
Wet, multi-disc (manual will detail friction plates, steel plates, and springs)
Reed Valve System:
Typically Boyesen or similar (manual will identify specific type and specifications)
Gearbox Kx125:
5-speed (manual will provide gear ratios)
Gearbox Kx250:
6-speed (manual will provide gear ratios)
Transmission Oil Type:
API GL-4 SAE 10W-30 (Manual will confirm exact specification and capacity)
Wheelbase Approximate:
1460-1480 mm (Varies by model, manual will provide exact)
Seat Height Approximate:
950-960 mm (Varies by model, manual will provide exact)
Dry Weight Kx125 Approximate:
94-95 kg (Manual will provide exact)
Dry Weight Kx250 Approximate:
98-100 kg (Manual will provide exact)
Fuel Tank Capacity:
8.0 Liters (Manual will confirm exact)
Front Wheel Size:
21 inch (Manual will confirm tire specifications and pressures)
Rear Wheel Size:
19 inch (Manual will confirm tire specifications and pressures)
Safety Certification:
Not applicable for off-road motorcycles in the same way as road vehicles. Manual focuses on mechanical safety.
Braking System Front:
Hydraulic disc (Manual will detail caliper, master cylinder, and fluid specifications)
Braking System Rear:
Hydraulic disc (Manual will detail caliper, master cylinder, and fluid specifications)
Frame Construction:
Perimeter frame, typically steel (Manual will provide frame inspection and repair guidelines)
Infotainment System:
N/A (Performance off-road motorcycle)
Rider Aids:
N/A (Performance off-road motorcycle)
Connectivity Features:
N/A (Performance off-road motorcycle)
Power Valve System:
Kawasaki Integrated Power Valve System (KIPS) for optimized powerband. Manual details adjustment and maintenance.
Oil Change Frequency:
Refer to 'Periodic Maintenance' section for specific intervals based on usage (e.g., hours of operation or rides).
Spark Plug Replacement:
Refer to 'Periodic Maintenance' section for recommended intervals and plug type (e.g., NGK BR9ES).
Air Filter Cleaning:
Frequent cleaning recommended based on riding conditions, detailed in 'Periodic Maintenance'.
Coolant Type:
High-quality coolant with anti-freeze and anti-corrosion properties (Manual will specify type and mixture ratio).
Brake Fluid Type:
DOT 4 (Manual will confirm exact specification)
2-Stroke Oil Mix:
High-quality 2-stroke premix oil (Manual will specify brand recommendations and mix ratio).
Fork Oil Grade:
Manual will specify exact fork oil viscosity (e.g., Showa SS-01, Bel-Ray 5W) and level.
Shock Oil Type:
Manual will specify shock absorber fluid type and specifications.
Common Wear Items:
Piston rings, clutch plates, chain and sprockets, fork seals, wheel bearings, swingarm pivot bearings.
Engine Tuning Considerations:
Proper jetting for altitude and temperature is critical for optimal performance and longevity. Manual provides detailed jetting tables and procedures.
Suspension Maintenance:
Regular fork oil and seal replacement, shock linkage lubrication, and adjustment of clickers are essential for handling.
Kawasaki Offroad Legacy:
Kawasaki has a long and successful history in motocross and off-road racing with the KX line, dating back decades.
Kx125 Kx250 Development:
These models represent a period of refinement in Kawasaki's two-stroke motocross technology, focusing on power delivery and handling.
Manufacturing Location:
Japan (Typical for Kawasaki motorcycles)
Motocross Championships:
The KX line, including models within this generation, has a strong record of success in professional motocross and supercross racing.
Industry Reviews General:
Models from this era were generally praised for their potent engines and competitive chassis, though specific reviews should be consulted.
