Kawasaki KX125 / KX250 service manual 1992-1993
Contents
1. Motorcycle Service Manual Quick Reference Guide 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 Electrical System Appendix This quick reference guide will assist you in locating a desired topic or procedure Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page O Refer to the sectional table of contents for the exact pages to locate the specific topic required KX125 Kawasaki KX250 Motorcycle Service Manual LIST OF ABBREVIATIONS ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s pounds s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s Read OWNER S MANUAL before operating Foreword This manual is designed primari y for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to2. descriptions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the motorcycle Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle For the same reason before installing a new part clean off any dust or metal filings 2 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a cross pattern This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 3 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 4 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a w
3. lose their original function once removed 18 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 19 Specifications Specification terms are defined as follows Standards Show dimensions or performances which brand new parts or systems have Service Limits Indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts 1 4 GENERAL INFORMATION Model Identification KX125 J1 Left Side View KX125 J1 Right Side View GENERAL INFORMATION 1 5 KX250 J1 Left Side View KX250 J1 Right Side View
4. the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substi tute tools may adversely affect safe operation We recommend that all repairs and scheduled maintenance be performed in accordance with this service manual To get the longest life out of your Motorcycle eFollow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled mainte nance e Use proper tools and genuine Kawasaki Motorcy cle parts Special tools gauges and testers that are necessary when servicing Kawasaki Motorcy cles are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the parts Catalog eFollow the procedures in this manual carefully Don t t
5. ake shortcuts e Remember to keep complete records of mainte nance and repair with dates and any new parts installed How to Use this Manual In preparing this manual we divided the product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the products system and assists in locating their chapters Each chapter in turn has its own compre hensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in personal injury or loss of life This caution symbol identifies special instructions or procedures which if not strictly observed could result in damag
6. e to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE O This note symbo indicates points of particular interest for more efficient and convenient operation indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before SOVI arriere OR 1 2 UOC CRONO Na ah nn OGAME 1 4 O 1 6 Periode Malntananca CASE cowania CKS ASKA parrot 1 10 Torque and Locking Agen Ein 1 11 Special Tools Seal iii anne 1 14 Cable Names Routiers en ink Hennen 1 18 R 1 2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed
7. ooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads 5 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 6 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is Stoddard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 7 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 8 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 9 Press A part installed using a press or driver such as a wheel bearing should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 10 Ball Bearing and Needle Bearing Do not remove any ball or needle bearings that a
8. re pressed in unless it is necessary If they are removed replace them with new ones When installing a bearing press it in with the marked side facing out using a suitable driver until it is bottomed Bearings should be pressed into place by pushing evenly the bearing race which is affected by friction 11 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole GENERAL INFORMATION 1 3 12 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little high temperature grease on the lips to reduce rubber to metal friction 13 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 14 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing su
9. rfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS in the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special lubricants 16 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Red Wire Strands Yellow Red Yellow Red 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed These replacement parts will be damaged or
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