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2004 KAWASAKI KX250F Motorcycle Service Repair Manual

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The Kawasaki KX250F, model code KX250-N1, is a motocross motorcycle produced in 2004, representing Kawasaki's strong commitment to the competitive 250cc four-stroke segment. Building on a legacy of off-road racing...
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2004 KAWASAKI KX250F Motorcycle Service Repair Manual
The Kawasaki KX250F, model code KX250-N1, is a motocross motorcycle produced in 2004, representing Kawasaki's strong commitment to the competitive 250cc four-stroke segment. Building on a legacy of off-road racing success, this model was engineered for performance and agility, featuring a liquid-cooled, four-stroke, single-cylinder engine with a displacement of 249 cc. Its design includes a 48mm inverted telescopic front fork and a New Uni-Trak rear suspension system, both offering adjustable damping, alongside front and rear petal disc brakes for reliable stopping power. These features contribute to its reputation for competitive handling and performance, making it a notable machine for off-road enthusiasts. This comprehensive Service Repair Workshop Manual in English provides detailed information for maintaining and repairing the 2004 Kawasaki KX250F. It covers a wide range of topics including General Information, Periodic Maintenance, Fuel System, Cooling System, Engine components (Top End, Right Side, Lubrication), Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, and the Electrical System, along with an Appendix. The manual offers professional-quality, step-by-step instructions, exploded diagrams, and factory-level detail, enabling enthusiast owners and mechanics to perform routine maintenance, troubleshooting, component replacement, and system overhauls, ultimately saving on repair costs and ensuring optimal performance.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX250F
Year:
2004
Model Code:
KX250-N1
Vehicle Type:
Motocross Motorcycle
👋 Introduction
Market Position
Target Audience:
Enthusiast owners, independent repair shops, mechanics seeking detailed factory-level information
Key Features
Manual Quality:
Professional Quality, Highly Detailed
Instruction Style:
Step-by-step instructions with highly detailed exploded pictures and diagrams
Value Proposition
Cost Saving:
Enables users to save money on repair bills by performing their own maintenance and repairs.
Delivery
Download Method:
Instant download upon payment completion
📋 Manual Details
Coverage
Coverage Areas:
General Information, Periodic Maintenance, Fuel System, Cooling System, Engine Top End, Engine Right Side, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix
Pagination
Page Count:
356
Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems
Systems Covered:
Engine (Top End, Right Side, Lubrication), Fuel System, Cooling System, Transmission, Final Drive, Brakes, Suspension (Front & Rear), Steering, Frame, Electrical System, Wheels, Tires
Procedures
Procedures Included:
Routine maintenance, troubleshooting, disassembly, assembly, repair, adjustments, component replacement, electrical diagnostics
Depth
Technical Depth:
Comprehensive (from basic maintenance to complete engine rebuilds and system overhauls), professional mechanic-level detail
📊 Manual Specifications
File Details
File Format:
PDF
Searchable:
Yes
Bookmarked:
Yes
Print Quality
Printable:
Yes (all pages)
Compatibility
Os Compatibility:
All Versions of Windows & Mac
Viewing
Reader Requirement:
Adobe PDF Reader
Zoom Functionality:
Yes (Zoom In/Out)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, Four-stroke, Single Cylinder
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 x 61.1 mm (2.8 x 2.4 in.)
Valve System:
DOHC, 4 valves
Fuel System
Fuel Delivery:
Keihin FCR37 carburetor
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Lubrication Type:
Semi-dry sump with oil cooler
🔧 Transmission
Gearbox
Transmission Type:
5-speed, return
Clutch
Clutch Type:
Wet, multi-disc
Final Drive
Final Drive Type:
Sealed chain
📐 Dimensions
Overall
Length:
2150 mm (84.6 in.)
Width:
800 mm (31.5 in.)
Height:
1255 mm (49.4 in.)
Wheelbase
Wheelbase:
1475 mm (58.1 in.)
Ground Clearance
Ground Clearance:
335 mm (13.2 in.)
Seat Height
Seat Height:
965 mm (38.0 in.)
Weights
Curb Weight:
97 kg (213.8 lbs)
🛡️ Safety Features
Braking System
Front Brake:
Semi-floating petal disc
Rear Brake:
Petal disc
Suspension
Front Suspension Type:
48mm inverted telescopic fork with rebound and compression damping
Rear Suspension Type:
New Uni-Trak with adjustable preload, compression and rebound damping
💡 Technology Features
Engine Management
Ignition System:
Digital CDI
Suspension Tech
Fork Technology:
48mm inverted cartridge fork with adjustable damping
Rear Shock Technology:
Adjustable Uni-Trak single shock system
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific hours/miles; typically every 5-10 hours of hard riding or as per manufacturer recommendation.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (refer to manual for specific intervals).
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or SH motorcycle oil (specific capacity in manual)
Coolant Type:
High-quality antifreeze coolant mixture (specific ratio and type in manual)
Known Issues
Common Wear Items:
Piston, piston rings, valve seals, clutch plates, chain and sprockets, fork seals (typical for motocross bikes of this era).
Troubleshooting Focus
Carburetor Tuning:
Carburetor jetting and adjustment for altitude and temperature changes is a common area of focus for optimal performance.
📚 Vehicle History
Brand Heritage
Kawasaki Offroad Legacy:
Kawasaki has a long and successful history in motocross and off-road racing, consistently developing competitive machinery.
Model Evolution
Kx250F Development:
The KX250F was a significant model for Kawasaki, marking its strong entry into the competitive 250cc four-stroke motocross segment. The 2004 model represented an early iteration of this platform, focusing on performance and handling.
🏆 Awards & Recognition
Motorcycle Press
Industry Recognition:
The KX250F platform, in general, has received numerous accolades and comparisons in motorcycle media for its performance and handling characteristics.
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