1991-1992 Kawasaki KX125, KX250 Motorcycle Service Manual
Addresses KX125 and KX250 systems including engine, fuel, cooling, electrical, and more. PN 99960-1040-01.
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Sample pages from the 1991-1992 Kawasaki KX125, KX250 Motorcycle Service Manual manual
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Kawasaki Models Covered & Key Technical Specifications
Models: Kawasaki KX125, Kawasaki KX250
Sub-models / Variants: K1
Build Years: 1991–1992
Technical Data:
- Engine type: 2-stroke, single cylinder, crankcase reed valve (KX125), piston reed valve (KX250)
- Cooling system: Liquid-cooled
- Displacement: 124 mL (KX125), 249 mL (KX250)
- Maximum horsepower: 29.1 kW @ 11,250 rpm (KX125), 39.4 kW @ 8,000 rpm (KX250)
- Transmission type: 6-speed constant mesh return shift (KX125), 5-speed constant mesh return shift (KX250)
- Fuel system: KEIHIN PWK36 (KX125), KEIHIN PWK38 (KX250)
- Transmission oil capacity: 0.7 L (KX125), 0.85 L (KX250)
- Fuel tank capacity: 8.5 L
Kawasaki Manual Features & Content Preview
Kawasaki KX125/KX250 Motorcycle Service Manual
- Covers 1991–1992 Kawasaki KX125 and KX250 motorcycles, providing technical specifications and service procedures for the K1 variant
- Official factory service publication, documenting maintenance for 2-stroke engines and chassis components
- Contains 47 exploded-view diagrams for system assembly and 11 distinct torque-specification tables
- Downloads to your account within seconds of checkout
- Permanent availability in your purchase account — no re-buy required
- Indexed PDF search covers every chapter and appendix
- Laid out for standard letter and A4 printing
- This 1991–1992 Kawasaki KX125/KX250 service manual is the primary reference used for factory-level maintenance, documenting engine performance, cooling systems, and drive train configuration for the K1-series builds.
What the Manual Documents:
The service documentation provides an organized breakdown of the KX125 and KX250 systems. Chapters detail general maintenance, the fuel system, cooling infrastructure, and engine internal components. Significant focus resides on the Engine Top End and Engine Right Side, where piston, cylinder, clutch, and external shift mechanism procedures are documented alongside exploded-view illustrations for reassembly. The guide also details suspension, steering, and electrical system diagnostics, concluding with specialized supplements for 1995–1998 models.
Specification Highlights:
Technical depth is provided through detailed tables covering clearances, capacities, and torque limits. Cylinder compression for the KX125 is listed at 755–1180 kPa, while the KX250 compression is 780–1220 kPa. The primary reduction gear torque is specified at 59 N-m (43 ft-lb) for the KX125. Transmission oil capacity for the KX125 is 0.7 L, while the KX250 is documented at 0.85 L. Reference for what an OEM service publication covers assists users in navigating the assembly protocols.
An official 1991–1992 Kawasaki KX125/KX250 factory service manual covering the K1-series motorcycles, documenting complete engine, chassis, and drivetrain specifications for professional-grade maintenance and diagnostic review across all major systems.
Document Reference: Official factory service manual; copyright 1991-1992 Kawasaki
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