1986 Kawasaki KX 125 Manual PDF

The 1986 Kawasaki KX 125 is a high-performance motocross motorcycle featuring a liquid-cooled 2-stroke 125cc engine, 6-speed transmission, Uni-Trak rear suspension, and advanced chassis design for competitive racing. Below are key sections covering specifications, maintenance procedures, troubleshooting, and technical data.

1. Specifications 2. Engine Maintenance 3. Chassis & Suspension 4. Electrical System 5. Carburetor Settings 6. Transmission & Clutch 7. Brake System 8. Routine Maintenance Schedule 9. Troubleshooting Guide 10. Parts & Accessories 11. Technical Diagrams

Specifications

Complete technical specifications for the 1986 Kawasaki KX 125 motocross bike.

ComponentSpecification
Engine TypeLiquid-cooled 2-stroke single
Displacement124cc
Bore x Stroke56.0 x 50.5mm
Compression Ratio8.4:1
CarburetorKeihin PE28
IgnitionCDI electronic
Transmission6-speed constant mesh
Final Drive520 chain
Suspension FrontAir-adjustable telescopic fork
Suspension RearUni-Trak swingarm
Brakes FrontSingle disc
Brakes RearSingle drum
Dry Weight91 kg (201 lbs)
Fuel Capacity7.5 liters (2.0 gal)

Engine Maintenance

Proper maintenance procedures for the 2-stroke engine.

  1. Spark Plug: NGK BR9ES, gap 0.6-0.7mm
  2. Fuel Mixture: 30:1 (premium unleaded with Kawasaki 2-stroke oil)
  3. Cylinder Head Torque: 22 Nm (16 ft-lbs)
  4. Piston Clearance: 0.045-0.055mm
  5. Coolant Capacity: 850ml, use ethylene glycol antifreeze
  6. Exhaust System: Regular cleaning of power valve mechanism

WARNING! Always allow engine to cool before maintenance. Use proper safety equipment.

Chassis & Suspension

Frame geometry and suspension adjustment procedures.

Adjustment Tip: Set sag to 95-100mm for optimal handling.

Electrical System

Complete electrical specifications and maintenance.

ComponentSpecification
Ignition Timing1.8mm BTDC (fixed)
Spark AdvanceElectronic CDI controlled
Lighting Coil30W AC output
BatteryNot applicable (magneto ignition)
Bulb Headlight35W/35W (if equipped)

Carburetor Settings

Standard carburetor jetting and adjustment specifications.

  1. Main Jet: #150 (standard)
  2. Pilot Jet: #55
  3. Needle Jet: 4GF-42, clip position 3rd from top
  4. Needle: 4GX1
  5. Air Screw: 1.5 turns out
  6. Float Height: 16.5mm
  7. Throttle Slide: #3.0

Note: Jetting may vary based on altitude and temperature conditions.

Transmission & Clutch

Gear ratios and clutch specifications.

Brake System

Brake specifications and maintenance procedures.

  1. Front Disc: Diameter 240mm, thickness 4.0mm
  2. Rear Drum: Diameter 110mm, lining thickness 4.0mm
  3. Brake Fluid: DOT 4
  4. Pad Wear Limit: 1.0mm minimum thickness
  5. Brake Lever Free Play: 2-3mm

CAUTION! Always replace brake pads in sets. Check fluid regularly.

Routine Maintenance Schedule

Recommended service intervals for optimal performance.

Service ItemEvery RaceEvery 3 RacesEvery Season
Air Filter Clean
Transmission Oil
Coolant Change
Piston Replacement
Wheel Bearing Check
Swingarm Bearing
Brake Inspection
Chain Adjustment

Troubleshooting Guide

Common issues and solutions for the KX 125.

SymptomPossible CauseCorrective Action
Hard startingFouled plug, stale fuelReplace spark plug, drain old fuel mixture
Poor top end powerClogged main jet, worn pistonClean carburetor, inspect piston and rings
Transmission slippingWorn clutch platesReplace clutch plates and springs
OverheatingLow coolant, stuck thermostatCheck coolant level, inspect cooling system
Poor suspensionWorn bushings, low oilReplace suspension linkage, change fork oil
Brake fadeContaminated pads, old fluidReplace brake pads, flush brake system

Parts & Accessories

Genuine Kawasaki parts and recommended aftermarket components.

Technical Diagrams

Reference diagrams available in the complete manual PDF.

Exploded views included for: - Complete engine assembly - Transmission components - Carburetor breakdown - Electrical system routing - Frame and suspension - Brake system components

Note: Full technical drawings with part numbers available in downloadable PDF.

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