Positioning:
High-performance motocross competition machine, successor to a long line of successful KX models.
Competitors:
Primary competitors include Yamaha YZ250, Honda CR250R, and KTM 250 SX.
Engine Type:
Liquid-cooled, two-stroke, single-cylinder engine.
Suspension Front:
Kayaba (Showa) 48mm Upside-down telescopic fork with adjustable compression and rebound damping.
Suspension Rear:
Uni-Trak linkage system with Kayaba (Showa) shock absorber, adjustable preload, compression, and rebound damping.
Brakes Front:
Hydraulic disc brake with 250mm rotor.
Brakes Rear:
Hydraulic disc brake with 240mm rotor.
Transmission:
5-speed constant mesh, return shift.
Engine Service:
Complete engine disassembly, assembly, inspection, repair, and troubleshooting.
Transmission Service:
Clutch, gearbox, and final drive maintenance and repair.
Chassis Suspension:
Front forks (cartridge/spring), rear shock absorber, linkage, swingarm, and steering system.
Brakes:
Front and rear brake system inspection, service, and bleeding procedures.
Electrical System:
Ignition system, lighting, charging system, and wiring diagrams.
Fuel System:
Carburetor disassembly, adjustment, cleaning, and fuel tank/line maintenance.
Cooling System:
Radiator, hoses, and coolant specifications and service.
Exhaust System:
Exhaust pipe and silencer inspection and service.
Bodywork Frame:
Frame inspection, seat, fuel tank, body panels, and graphics removal/installation.
Troubleshooting:
Diagnostic procedures for common problems and fault finding.
Estimated Pages:
Approx. 300-400 pages (typical for this model's factory manual).
Type:
Factory Service Repair Manual
Engine Mechanical:
Cylinder head, piston, connecting rod, crankshaft, valve train, lubrication system.
Engine Electrical:
CDI ignition, spark plug, stator, flywheel, wiring harness.
Transmission Drivetrain:
Gear shifting mechanism, clutch plates, basket, gears, bearings.
Suspension Steering:
Front fork oil levels, pressures, seal replacement; rear shock adjustments, linkage bearing service.
Braking System:
Hydraulic lines, caliper piston service, master cylinder overhaul, brake pad replacement.
Wheels Tires:
Spoke tensioning, rim inspection, tire mounting, wheel bearing service.
Fuel Carburetion:
Keihin PWK carburetor tuning, jetting, float bowl maintenance, choke operation.
Cooling Radiator:
Radiator flush, coolant type (e.g., 50/50 ethylene glycol mix), water pump seal replacement.
Frame Body:
Frame integrity checks, handlebar replacement, footpeg mounting.
Disassembly Assembly:
Detailed step-by-step instructions for component removal and reinstallation.
Inspection Measurement:
Torque specifications for all fasteners, wear limits for engine components (piston, cylinder bore), bearing clearances.
Troubleshooting Diagnostics:
Flowcharts and guides for identifying and resolving common performance issues.
Maintenance Adjustments:
Carburetor jetting adjustments, chain tensioning, valve clearance checks (if applicable to this 2-stroke model), spark plug gap.
Special Tools:
Listing and description of specialized tools required for specific procedures (e.g., flywheel puller, clutch holder tool).
Wiring Diagrams:
Comprehensive electrical schematics for easy diagnosis of electrical faults.
Depth:
Comprehensive rebuild and diagnostic capabilities, suitable for professional mechanics and experienced DIY enthusiasts.
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Bore X Stroke:
66.4 x 72.0 mm
Compression Ratio:
8.8:1 (typical for this era KX250)
Valve System:
Reed valve intake, KIPS (Kawasaki Integrated Powervalve System) exhaust port.
Horsepower Est:
Approx. 45-50 HP at the crank (estimated, factory data not always published for competition models).
Torque Est:
Approx. 30-34 lb-ft at the crank (estimated).
Carburetor:
Keihin PWK38 (38mm flat slide carburetor) with throttle position sensor (TPS).
Fuel Type:
Unleaded gasoline, 91 octane (minimum recommended for optimal performance).
Premix Ratio:
50:1 ratio of high-quality 2-stroke oil to gasoline.
Type:
5-speed constant mesh, return shift
Clutch:
Wet multi-disc, manual operation.
Final Drive:
#520 O-ring sealed chain.
Kips System:
Kawasaki Integrated Powervalve System (KIPS) for improved low-to-mid range power delivery and top-end acceleration.
Length Overall:
Approx. 2170 mm (85.4 in)
Width Overall:
Approx. 800 mm (31.5 in)
Height Overall:
Approx. 1255 mm (49.4 in)
Wheelbase:
Approx. 1475 mm (58.1 in)
Ground Clearance:
Approx. 355 mm (14.0 in)
Seat Height:
Approx. 965 mm (38.0 in)
Dry Weight:
Approx. 95 kg (209.4 lbs)
Curb Weight:
Not typically specified by Kawasaki for this model.
Fuel Capacity:
8.0 liters (2.1 US gal)
Safety Features:
Designed for closed-course competition; no safety ratings typically apply to street use.
Braking Performance:
Powerful hydraulic disc brakes front and rear for strong stopping power.
Suspension Stability:
Adjustable suspension provides optimal handling and stability over varied terrain.
Frame Construction:
High-strength perimeter frame for rigidity and rider feedback.
Features:
N/A (Competition motocross bike, no infotainment systems).
Features:
N/A (Focus is on rider control and mechanical feedback).
Features:
N/A (No electronic connectivity features).
System:
KIPS (Kawasaki Integrated Powervalve System) for optimizing power delivery across the rev range via electronic control of the exhaust port timing.
Oil Change:
Transmission oil (Kawasaki Genuine Gear Oil SAE 10W-30 or equivalent) should be changed every 10-15 hours of operation.
Air Filter:
Clean or replace the air filter every 5-10 hours of operation, more frequently in dusty conditions.
Spark Plug:
Inspect spark plug (NGK BR9EG or equivalent) every 10-15 hours, replace as needed. Check gap (0.6-0.7 mm).
Chain Tension:
Adjust drive chain free play (20-30mm) every 5-10 hours.
Engine Top End:
Top-end rebuild (piston and rings) recommended every 25-40 hours of hard use.
Engine Oil Type:
High-quality 2-stroke motorcycle oil, pre-mix ratio 50:1.
Transmission Oil Type:
Kawasaki Genuine Gear Oil SAE 10W-30 (or equivalent API GL-4 specification).
Coolant Type:
50/50 mixture of ethylene glycol-based coolant and distilled water.
Fork Oil:
Front fork oil: Showa SS-07 or equivalent (SAE 5W). Capacity: 330-345 ml per leg (refer to manual for exact adjustment).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Clutch Wear:
Clutch plates can wear prematurely with aggressive riding; regular inspection and adjustment are necessary.
Carburetor Fouling:
Carburetor jetting may require fine-tuning based on altitude, temperature, and riding style to prevent fouling or lean conditions.
Kips System Sticking:
KIPS system can accumulate carbon deposits and may require periodic cleaning to ensure proper operation.
Suspension Seals:
Fork and shock seals can leak over time due to harsh riding conditions; require regular inspection and potential replacement.
Heritage:
Kawasaki has a long and storied history in motocross, with the KX line being a dominant force for decades.
Evolution 2008:
The 2008 model represented a refinement of the successful KX250 platform, focusing on improved suspension, chassis geometry, and engine tuning for enhanced competition performance.
Predecessors:
Builds upon the legacy of the KX250, which transitioned from air-cooled to liquid-cooled engines and saw continuous chassis and engine development.
Manufacturing Location:
Japan
Production Years:
The KX250 two-stroke was produced through the 2007 model year in many markets, with some regions potentially offering the 2008 model as a carry-over or updated version. Kawasaki later introduced a KX250F (four-stroke).
