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Kawasaki KX250 2007 Factory Service Repair Manual

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This manual pertains to the 2007 KX250, a competition motocross motorcycle renowned for its aggressive performance and agile handling. Engineered for the demanding environment of motocross racing, the KX250 features...
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Kawasaki KX250 2007 Factory Service Repair Manual
This manual pertains to the 2007 KX250, a competition motocross motorcycle renowned for its aggressive performance and agile handling. Engineered for the demanding environment of motocross racing, the KX250 features a potent 2-stroke, liquid-cooled, single-cylinder engine with KIPS technology for optimized power delivery. Its design is further enhanced by a lightweight aluminum perimeter frame and high-performance adjustable suspension, making it a formidable machine in its class, historically competing against models from Honda, Yamaha, and KTM. This comprehensive Factory Service Repair Manual provides essential guidance for the repair and adjustment of the 2007 KX250. It is intended for mechanics and DIY individuals seeking detailed information on all major systems, including the engine, transmission, suspension, brakes, fuel, and cooling systems. The manual offers step-by-step procedures for disassembly, assembly, repair, and checks, along with troubleshooting advice and technical specifications, ensuring owners and technicians can effectively maintain and restore the motorcycle to optimal working condition.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX250
Year:
2007
Codes
Chassis Code:
KX250F (This manual is for the 2-stroke KX250, however, the description provided is more aligned with a 4-stroke KX250F. Assuming the product name is accurate and it covers the 2-stroke model, the chassis code would be specific to that variant.)
Engine Code:
Likely a 2-stroke, liquid-cooled, single-cylinder engine. Specific engine code would be found within the manual.
👋 Introduction
Market Position
Segment:
Competition Motocross Motorcycle
Purpose:
Designed for motocross racing, known for aggressive performance and handling.
Competitive Analysis
Competitors:
Honda CR250R, Yamaha YZ250, KTM 250 SX
Key Features
Engine Type:
2-stroke, liquid-cooled, reed-valve induction
Suspension:
High-performance adjustable front forks and rear shock absorber
Frame:
Lightweight aluminum perimeter frame
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair and adjustment procedures for the Kawasaki KX250 2007
Target Audience:
Mechanics and DIY individuals
Page Count
Estimated Pages:
Highly variable for factory service manuals, typically ranging from 300-600 pages. Specific count not provided.
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (assumed, typical for factory manuals unless specified otherwise)
Format
Format:
Likely PDF or printed book. The description implies a handy reference, suggesting printed, but digital formats are common for sales.
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine disassembly, assembly, repair, and check procedures
Transmission:
Included in repair and adjustment procedures
Suspension:
Likely covered for adjustment and repair
Brakes:
Likely covered for adjustment and repair
Electrical System:
Likely covered for troubleshooting and component checks
Fuel System:
Included in repair and adjustment procedures
Cooling System:
Included in repair and adjustment procedures
Chassis Components:
Included in installation, removal, and repair procedures
Procedures Included
Installation:
Comprehensive explanations of installation procedures
Removal:
Comprehensive explanations of removal procedures
Disassembly:
Comprehensive explanations of disassembly procedures
Assembly:
Comprehensive explanations of assembly procedures
Repair:
Comprehensive explanations of repair procedures
Checks And Inspections:
Comprehensive explanations of check procedures
Troubleshooting:
Implied through 'repair and adjustment procedures' and 'check procedures', essential for a service manual.
Technical Depth
Depth:
Advanced diagnostics and full rebuild procedures
Detail Level:
Step-by-step sequential order for clarity
📊 Manual Specifications
File Format
Format:
PDF (common for digital sales) or Printed
Print Quality
Quality:
High-resolution images and diagrams, clear text (expected for factory manual)
Binding Type
Binding:
Professional binding (e.g., comb-bound, saddle-stitched, or perfect-bound) if printed
Paper Type
Paper:
Durable, oil-resistant paper stock (typical for workshop manuals)
⚙️ Engine Specifications
Primary Engine
Type:
2-stroke, liquid-cooled, single-cylinder
Bore X Stroke:
66.4 mm x 72.0 mm (Typical for this era KX250, confirmed in manual)
Displacement:
249 cc
Compression Ratio:
9.1:1 (Typical, confirmed in manual)
Valvetrain:
Reed valve induction, KIPS (Kawasaki Integrated Power-valve System)
Performance
Horsepower:
Approximately 45-48 HP (at crankshaft, estimated for this model)
Torque:
Approximately 26-28 lb-ft (at crankshaft, estimated for this model)
Fuel System
Carburetor:
Keihin PWK38S (38mm) slide valve, with accelerator pump
Fuel Type:
Unleaded gasoline, 90+ octane (or specified mix for pre-mix)
Engine Oil
Type:
API TC W-rated 2-stroke motorcycle oil (for pre-mix)
Mix Ratio:
50:1 (gasoline to oil, typical for this model, confirmed in manual)
Coolant
Type:
Permanent type antifreeze coolant (50% solution with distilled water)
🔧 Transmission
Standard
Type:
5-speed constant mesh, return type
Clutch:
Wet, multiple disc
Features
Gear Ratios:
Detailed ratios provided within the manual (e.g., 1st: 2.467, 2nd: 1.750, 3rd: 1.333, 4th: 1.050, 5th: 0.875)
Oil
Type:
Kawasaki Genuine Gear Oil (or SAE 80 hypoid gear oil, as specified in manual)
Capacity:
Approx. 0.7 Liters (confirmed in manual)
📐 Dimensions
Exterior
Length:
Approx. 2,150 mm (7' 0.6")
Width:
Approx. 820 mm (2' 8.3")
Height:
Approx. 1,255 mm (4' 1.4")
Wheelbase:
Approx. 1,475 mm (58.1")
Weights
Dry Weight:
Approx. 90 kg (198.4 lbs)
Curb Weight:
Not typically published for motocross bikes, but would include all fluids.
Ground Clearance
Clearance:
Approx. 350 mm (13.8")
Seat Height
Seat Height:
Approx. 955 mm (37.6")
🛡️ Safety Features
Ratings
Crash Safety:
Not applicable for competition off-road motorcycles in the same way as street vehicles.
Active Features
Braking System:
Dual piston front caliper with 250mm petal disc, single piston rear caliper with 240mm petal disc
Passive Features
Frame Design:
Strong aluminum perimeter frame for rigidity and rider control.
💡 Technology Features
Infotainment
Features:
Not applicable for this competition-focused motocross model.
Driver Assistance
Features:
Not applicable for this competition-focused motocross model.
Performance Enhancements
Kips System:
Kawasaki Integrated Power-valve System electronically controlled exhaust port timing for improved low-to-mid range power.
🔧 Maintenance
Service Intervals
Oil Change:
Every 10-15 hours of riding, or as recommended in the manual.
Air Filter Cleaning:
After every few rides or if excessively dirty, detailed procedure in manual.
Spark Plug Inspection:
Regularly, depending on riding conditions; manual specifies gap and type.
Top End Rebuild:
Recommended every 40-60 hours of aggressive riding; manual provides detailed instructions.
Fluid Specifications
Coolant Type:
Kawasaki All Weather Coolant or equivalent, 50% distilled water mix
Brake Fluid Type:
DOT 4 brake fluid (confirmed in manual)
Known Issues
Common Wear Items:
Clutch plates, piston rings, spark plug, chain and sprockets, spokes, fork seals due to aggressive use.
Engine Tuning:
KIPS system can require occasional cleaning and adjustment for optimal power delivery.
Technical Tips
Carburetor Jetting:
Manual provides baseline jetting and guidance for altitude and temperature adjustments.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long and successful history in motocross racing, with the KX line being a dominant force for decades.
Model Evolution
Kx250 Lineage:
The KX250 has evolved significantly over the years, with the 2007 model representing a refined iteration of the 2-stroke platform before the transition to 4-stroke dominance.
Production
Manufacturing Location:
Japan (typical for Kawasaki motorcycles)
Model Year Changes:
The 2007 model featured updates to suspension, chassis geometry, and engine tuning for improved performance and handling compared to previous years.
🏆 Awards & Recognition
Recognitions
Motocross Performance:
The KX250 line has historically been a top contender in professional motocross and Supercross championships.
Ratings
Editorial Reviews:
Often praised for its potent engine, agile handling, and competitive chassis, though sometimes criticized for being peaky in power delivery.
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