2004 Model Information

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1 Version: 4 Jun Model Information MARKETING CODE: KX125M MODEL NAME: KX125 Note: While material contained herein may be used in the preparation of press releases, technical service material and other SP and marketing material, please keep in mind that this information is intended for internal use only. All data reflect factory tests. All data subject to change without notice. KAWASAKI HEAVY INDUSTRIES, LTD. Consumer Products & Machinery Company 1-1 Kawasaki-Cho, Akashi City, Hyogo Pref Japan Tel: 81-(0) Fax: 81-(0)

2 OVERALL CONCEPT Completely redesigned for 2003, the KX125 has received a number of modifications to further improve engine and chassis performance. In the eternal quest for more power, an increase at one end of the rev spectrum usually means a drop at the other. However, Kawasaki engineers have succeeded in boosting lowand mid-range power, and actually managed a small increase at the top end as well. The race-proven perimeter frame benefits from a new linkage system for the Uni-Trak rear suspension that both improves suspension action and allows a lighter frame construction, revised fork settings and an improved riding position. The KX125 s key sales features can be summarised as follows: Improved engine performance revised combustion chamber with higher compression, improved piston/ring design, new expansion chamber, improved KIPS valve, new 2-stage reed valve with overlapping reeds, redesigned carb holder and airbox, revised ignition timing Improved handling and riding position Uni-Trak rear suspension with new linkage system offers greater traction, revised front fork settings for improved handling, new seat and expansion chamber improve riding position 2004MY KX125 Model Information Page: 2

3 KEY SALES FEATURES IMPROVED ENGINE PERFORMANCE Engine * Reshaped combustion chamber raises the compression for increased low- and midrange output, and crisper throttle response. * New piston ring reduces ring pressure (from 5.6 N m to 3.8 N m), for improved throttle response. * Improved KIPS valve design reduces the gap between the valve and port when the valve is fully closed for improved low-rpm power. (Photo 1) 1 03MY 04MY * Expansion chamber redesigned for more power in the mid-range and on top-end. * New 2-stage reed valves use carbon fibre reeds as last year, however, the weave direction has been rotated to a 45 angle. By increasing the flexibility of the reeds, low- and mid-range torque characteristics are improved. To prevent over-flexing of the reeds at high rpm and to stiffen them, a second layer of smaller, glass fibre reeds (also with 45 weave pattern) reinforce the main reeds. The result is the best of both worlds: highly responsive low/mid-range with the performance of stiffer reeds at high rpm. (Photo 2) 2 03MY 04MY * New carb holder and airbox duct give a straighter flow of incoming air for improved throttle response at very-low and low-rpm. 2004MY KX125 Model Information Page: 3

4 * A reduction in diameter of the primary drive gear s oil seal contact area (from 32 mm to 31.4 mm) reduces frictional loss and contributes to the improved throttle response of the new engine. (Photo 3) 3 * Revised ignition timing further boosts performance and improves reliability by reducing irregular combustion. IMPROVED HANDLING & RIDING POSITION Engine * A smaller expansion chamber centre section contributes to the improved riding position by allowing the rider greater freedom of movement. Frame * The most significant modification to the lightweight steel perimeter frame is the newlink Uni-Trak system. Additionally, the thickness and shapes of the upper cross tubes and engine mounts have been modified to idealise the stiffness balance for enhanced cornering performance and improved durability. Further, the footpeg location is now 3 mm higher for greater ground clearance when banked over and to complement the improved riding position. (Photos 4,5) MY 04MY * The rear brake pedal is now mounted 11.5 mm higher for increased ground clearance, and to suit the new riding position. 2004MY KX125 Model Information Page: 4

5 Front Suspension * New Kayaba bladder fork features check valves on the bladders to control their internal pressure. The result is improved damping and better fork action throughout the stroke. (Photo 6) 6 Rear Suspension * The improved Uni-Trak rear suspension system uses a newly designed link and a new operating system. Unlike the 03 chassis in which the link pivoted on the frame, in the new system, a newly designed link pivots on the swingarm. The advantages are twofold: first, the brunt of the suspension loads are now absorbed by the swingarm, allowing a lighter frame construction. The second benefit is that the shock absorber now moves in an outward arc as it compresses, rather than moving out and back in. This smoother, more stable action significantly improves traction. (Photos 7,8) 7 8 Styling & Bodywork * Flatter seat improves riding position and raises the seat height 8 mm. New seat cover texture resists slipping. 2004MY KX125 Model Information Page: 5

6 ADDITIONAL FEATURES Engine * 124 cm 3 liquid-cooled, two-stroke Single with crankcase reed valve induction. * A new cylinder features a wider radius at the upper corners of the exhaust port rib to reduce piston friction and improve piston and piston ring durability. * New cylinder base gasket is now symmetrical for easier maintenance. (Photo 9) MY 04MY 03MY 04MY * Cylinder cover changed from plastic to aluminium for improved sealing. (Photo 10) * A new piston relocates the piston ring locating pin at the exact rear of the piston. This ensures even heating/expansion of the piston ring and improves reliability of both the pin and the ring. (Photo 11) 11 03MY 04MY * With the exception of new settings, the TMX38x carburettor with arch-shaped slide remains unchanged. This unusual slide shape helps to concentrate the incoming charge more towards the centre of the intake tract for increased power in the higher rpm ranges. Also fitted is a semi-primary bleed needle jet that homogenises the fuel air mixture, contributing to sharp throttle response across the rev range. 2004MY KX125 Model Information Page: 6

7 * New crankshaft features increased clearance between the connecting rod big-end and the nylon crankcase stuffer for better lubrication of the big-end bearing. New connecting rod of stronger steel is more durable and improves reliability. (Photo 12) 12 * A new casting for the left crankcase is more rigid and prevents oil from seeping out between the cases. Additionally, the shape of the clutch cable hole has been changed to improve cable-to-case sealing (via an O-ring used on the cable instead of the previous bushing), and the breather hole has been relocated to prevent transmission oil from blowing out. * A slightly thicker generator cover gasket improves sealing. * New radiator has stronger side mounting brackets, preventing deformation by the rider s knees and by other impacts. (Photo 13) 13 Chassis * The swingarm is also new, and features a new cast bracket just aft of the shock to suit the new link, new forged axle holders (like those of the KX250N) which are stronger, and lighter, smaller diameter chain adjuster bolts (reduced from 10 mm to 8 mm). Plastic plugs now cover the holes in the swingarm beams to prevent the ingress of mud and dirt. The new swingarm features the tapering, hydroformed beams of the 03 model but is about 20 mm longer (max. length increased from mm to mm). * The sub-frame benefits from a stronger silencer mounting bracket and a smaller side cover mounting bracket. * Rear frame pop nut has reduced height for lower weight. * New engine mounting bolts made of stronger material can be torqued tighter and stay tight better. * A stronger igniter bracket is fitted. 2004MY KX125 Model Information Page: 7

8 * Other modifications to the 48 mm inverted fork include a longer interior slide bushing for improved action, a waisted interior cylinder for reduced weight, and more compact axle brackets with a new clamping method. (Photo 14) 14 * Restyled fork guards are shared with the KX250N and look great. * While the thin-wall aluminium triple clamps remain unchanged, the top nut is now made of lightweight aluminium instead of steel, and the washer below it is a thin (1 mm) stainless steel piece instead of the 03 model s thicker mild steel washer. * As before, the aluminium steering stem is tapered for low weight. * The actuating rods for the Uni-Trak linkage are new. A one-piece forged rod replaces the 03 model s two-piece extrusions. Also new are the sleeve-rod bushings, which are now captured by stepped washers (the washers stay in place better). A new D-head rod bolt eases maintenance (no wrench needed). * In addition to a new spring and revised damping settings, the rear shock rod length is 20 mm longer to suit the new link, and a drain bolt has been added to the shock for easy oil changing. * Front brake line is now routed directly rather than under the calliper as on the 03 model, resulting in a slightly lighter brake hose. * Dual-piston front brake calliper uses 27 mm pistons and is operated by a master cylinder with an 11 mm piston. * One-piece rear brake master cylinder is compact and lightweight and operates a 240 x 4 mm disc. Brake master cylinder rod length shorted 12 mm to suit new brake lever position. * The front axle is 9 mm shorter and the axle collar is also shorter and lighter (both are common with the KX250N). * Drive chain length increased from 112 to 114 links (now same as KX250). * A stronger chain guard of more durable material is also fitted. * 1-piece aluminium front and rear wheel spacers for low weight. * Fuel tank now uses an oblong mounting hole for easier maintenance. Other * Optional chassis parts include a lower seat (8 mm), a 20-inch front rim, a selection of aluminium and steel front and rear sprockets, different fork and shock springs, and solid brake discs. 2004MY KX125 Model Information Page: 8

9 COLOUR(S) * Lime Green with hot new graphics. 2004MY KX125 Model Information Page: 9

10 SPECIFICATIONS ENGINE Type Displacement Bore and Stroke Compression ratio Induction Fuel system Ignition Starting Lubrication KX125-M2 Liquid-cooled, 2-stroke Single with KIPS 124 cm x 54.5 mm 10.9:1 (low speed); 8.3:1 (high speed) for EUR 11.1:1 (low speed); 8.5:1 (high speed) for USA/CAN/AUS 6-petal carbon-fibre crankcase reed valve Carburettor: Mikuni TMX38x Digital CDI Primary kick Pre-mix (32:1) DRIVETRAIN Transmission Final drive Primary reduction ratio Gear ratios: 1st 2nd 3rd 4th 5th 6th Final reduction ratio Clutch 6-speed, return Chain (64/20) (31/13) (26/14) (26/17) (22/17) (27/24) (25/25) (51/13) Wet multi-disc, manual FRAME Type Wheel travel: front rear Tyre: front rear Caster (rake) Trail Steering angle (left/right) Perimeter, high-tensile steel 300 mm 310 mm 80/ M 100/ M mm 42 / MY KX125 Model Information Page: 10

11 SUSPENSION Front: Type Compression damping Rebound damping Rear: Type Compression damping Rebound damping Spring preload KX125-M2 48 mm upside-down cartridge-type telescopic fork 16-way 16-way New Uni-Trak 16-way 16-way Fully adjustable BRAKES Front: Type Calliper Rear: Type Calliper Single semi-floating 250 mm disc Dual-piston Single 240 mm disc Single-piston DIMENSIONS Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Fuel capacity 2,165 mm 840 mm 1,265 mm 1,470 mm 340 mm 945 mm 87 kg 8.2 litres PERFORMANCE Maximum power Maximum torque 30.2 kw {41.0 PS}/ 11,500 rpm 26.5 N m {2.70 kgf m}/ 10,500 rpm The specifications mentioned here apply to and have been achieved by production models under standard operating conditions. We intend only to give a fair description of the vehicle and its performance capabilities but these specifications may not apply to every machine supplied for sale. Kawasaki Heavy Industries, Ltd. reserves the right to alter specifications without prior notice. Equipment illustrated and specifications may vary to meet individual markets. 2004MY KX125 Model Information Page: 11

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