1999-2002 Kawasaki KX(125-250) Service & Repair Manual

KX125 Kawasaki KX250 Motorcycle Service Manual Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

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 w ith the black tab on the edge at each lable 01 contents page. • Refer to the sectional table of contents for the exact pages to locate the specific top ic required. Quick Reference Guide General Information Fuel System Cooling System Engine Top End Engine Right Side Engine Removal/Installation Engine Bottom EndlTransmission WheelslTires Final Drive Brakes Suspension Steering Electrical System Appendix 1 • 2 • 3 • 4 • 5 • 6 • 7 • 8 • 9 • 110. 11 • 12. 13. 141 Downloaded from www.Manualslib.com manuals search engine

KX125 KX250 Motorcycle Service Manual Downloaded from www.Manualslib.com manuals search engine

1 1 LIST OF ABBREVIATIONS A ampere(s) Ib pound(s) ABDC after bottom dead center m maler(s) AC alternating current min minule(s) AlOe after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before lop dead center p~ pound{s) per square inch ·C degree(s) Celsius revolution DC direct current 'pm revolution{s) perminute , F larad(s) TOC lop dead center 'F degree(s) Fahrenheit TlA 10lal indicator reading \ ft foot, feel V voll(S) 9 gram{s) W watt(s) h hour(s) n ohm(s) 1 L liter(s) 1 1 Read OWNER'S MANUAL before operating Downloaded from www.Manualslib.com manuals search engine

Foreword This manual is designed primarily fo r use by trained mechanics in a property equipped shop. However, it contains enough detail and basic in formation to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge at 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 insuff ic ient experience or doubts as to his ability to do the work, all adjustments, maintenance, and repair should be carried out on ly 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 substitute tools may adversely affect safe operat ion. To get the longest life out of your motorcycle: • Follow the Pe riodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki motorcycle parts. Special tools, gauges, an d testers that are necessary when servicing Kawasaki Motorcycles are in troduced by the Special Tool Manual. Genui ne parts provided as spare parts are listed in the Pa rts Catalog. • Follow the procedures in this manual carefully. Don't ta ke shortcuts. • Remember to keep complete records of maintenance and repair wi th 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 lor a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Cont ents. The Periodic Ma intenance Chart is located in the General In formation chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to t he Periodic Maintenance Chart firs t. The chart tells you how frequenlly to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical Syst em chapter. Then , use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whe never you see these WARNI NG and CAUTION symbols. heed their i nstructi ons! Always follow safe operating and maintenance practices. AWARNING This war ning sy mbo l identif ies special ins truc- tions or procedures which, if nat correctly fol- lowed, could res ult in personal inj ury, or loss of life. CAUTION This caution symbol identifies special instructions or proced ures which , if not strictly ob- served, cou ld resu lt in damage ta or destruct ion of equipment. This manua l contains fou r more symbols ( in addition to WARNING and CAU TION) wh ich wi ll help you distinguish different types of information. NOTE o This note symbol indicates points of particular in- terest for more efficient and convenient operation. • Indicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it fo llows. It also precedes the text of a 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 01 Contents. In these illustrations you will lind the instructions indicating which parts require specilied ti ghtening torque, oil, grease or a locking agent during assembly. Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing .. ... ................................................ ................... ...... .. .... ... . .. ......... .. ................................. ...... .. ... ........ .... .. 1-2 Model Identification .. ... .............. .... .. ... ........ ... ..... .... ................................................ .. ..... .. .. .... .... .. .. ... .. ..... ... ........... .. .. . 1·4 General Specifications .. ................... .... . ... .... ... .. ... ............................................... ..... ........... .. .. .. .. .... .. .. .. .... ... .. .. . .. ... .. .... ... 1·8 Periodic Maintenance Chart ... ... ... ... . .... .. .... .. ............................. ......................... .. . .... .. .... ... ... . .. ....... ... . ... .. .. ................... 1-15 Torque and Locking Agent .... ..................................... .. .. . ... ..... .... .. ............... ....... .. ............................................ .. .. .. 1-16 Special Tools ...................................... .. .. ... .. ... . ...................................................... ........................... 1·19 Cable, Wire and Hose Rou t ing ... ...... .. .... .... ... .. .. .. .. . ... . ... ..................................................... .. .. .. ........... .. .......... .. ...... .. .... 1·23 Downloaded from www.Manualslib.com manuals search engine

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection seMce or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations. noles, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items thai require particular attention during the removal and reinstallation or disassembly and reassembly 01 general parts. Especially note the following: (1 ) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Disconnect the ground (-) wire from the battery before perlorming any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated wtlile disconnecting the wires from electrical parts, as well as damage to Ihe electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing botts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to lollow the sequence. When installing a part with several botts, nuts, or screws, start them all in their holes and tighten them to a snug fil, thus ensuring that the part has been installed in its proper location. Then, lighten them to the specified torque in the tightening sequence and method indicated. If lightening sequence instructions are not given, lighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the botts, nuts, or screws thai are retaining the part a 1/ 4-lurn before removing them. (5) Torque When torque values are given in this Service Manual, use them. Either too little or 100 much torque may lead to serious damage. Use a good quality, reliable torque wrench. (6) 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 wooden or plastic·faced mallet. Use an impact driver for screws (particularly for the removing screws held by non·permanent locking agent) in order to avoid damaging the screw heads. (7) Edges Walch for sharp edges, as they could cause injury through careless handling, especially during maiO( engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over. (8) High·Flash Point Solvenl A high·flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use 01 any solvent. (9) Gasket, O-Ring Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter Irom the mating surlace of the gasket or O·ring to ensure a perlectly smooth surface to prevent oil or compression leaks. (10) Uquid Gasket, locking Agent Clean and prepare surlaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage. ( 11 ) Press When using a press or driver to inslall a part such as a wheel bearing, apply a small amount 01 oil to the area where the two parts come in conlact to ensure a smooth lit. ( 12) Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manulacturer and size marks lacing out. applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component. (13) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When presSing in an oil or grease seal wtlich has manufacturer's marks, press it in with the marks facing out. • 1 Downloaded from www.Manualslib.com manuals search engine

1999-2002 Kawasaki KX(125-250) Service & Repair Manual

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