Vehicle Segment:
Motocross / Off-Road Competition Motorcycle
Key Competitors:
Yamaha YZ250, Honda CR250R, KTM 250 SX
Manual Value Proposition:
Provides essential, factory-level technical data for DIY maintenance and repair, saving significant costs compared to dealership service.
Vehicle Reputation:
Known for its strong, competitive performance in its class, requiring dedicated maintenance to sustain peak performance.
Primary Coverage:
Full Service, Repair, Workshop Procedures
Additional Coverage:
Troubleshooting, Diagnostics, Maintenance Schedules, Specifications
Estimated Pages:
Likely 500+ (Typical for a comprehensive factory service manual)
Type:
Factory Service Manual / Workshop Manual
Format:
Digital Download (PDF compatible)
Engine:
Top End (Cylinder, Piston, Rings), Bottom End (Crankshaft, Connecting Rod, Bearings), Lubrication System, Cooling System (Radiator, Water Pump), Fuel System (Carburetor, Fuel Tank, Lines), Ignition System (CDI, Spark Plug), Exhaust System
Transmission:
Clutch Assembly, Gearbox Internals, Shift Mechanism, Sprockets, Chain Maintenance
Chassis And Suspension:
Frame, Front Fork (Internal Components, Seals), Rear Shock Absorber, Swingarm, Linkages, Wheel Bearings, Steering Head Bearings
Brakes:
Front and Rear Hydraulic Disc Brakes, Caliper Overhaul, Master Cylinders, Brake Fluid Replacement, Bleeding Procedures
Electrical:
Wiring Diagrams, Lighting System, Ignition Switch, Kill Switch, Battery Maintenance (if applicable, typically kick-start only for this era), Coil Specifications
Bodywork And Controls:
Body Panels, Seat, Handlebars, Levers, Cables (Throttle, Clutch), Footpegs
Maintenance:
Regular Servicing, Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement, Coolant Flush
Repair:
Engine Rebuilds (Top and Bottom End), Carburetor Tuning and Rebuild, Suspension Overhaul, Brake System Repair, Clutch Replacement, Gearbox Repair, Bearing Replacements
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Problem Solving, Common Issues and Solutions
Depth:
Comprehensive from basic user maintenance to complete engine and transmission overhauls, including factory specifications and tolerances.
Engine Type:
2-Stroke, Single Cylinder
Displacement:
249 cc (15.25 cu. in.)
Bore X Stroke:
66.4 x 72.0 mm
Compression Ratio:
Approximately 8.7:1 to 9.4:1 (depending on specific model year and configuration)
Cooling System:
Liquid-Cooled
Horsepower:
Approx. 45-50 HP (at Crankshaft, varies by year and tuning)
Torque:
Approx. 28-30 lb-ft (at Crankshaft, varies by year)
Carburetor Type:
Keihin PWK38S (or similar 38mm flat slide carburetor)
Fuel Type:
Unleaded Gasoline (min. 91 Octane Recommended)
Premix Ratio:
50:1 (2-stroke oil to gasoline) with high-quality 2-stroke racing oil
Gear Ratios:
Detailed in manual, specific ratios for each gear (e.g., 1st: 2.46, 2nd: 1.86, 3rd: 1.50, 4th: 1.22, 5th: 1.00)
Clutch Type:
Wet Multi-Plate
Final Drive:
Chain Driven
Transmission Oil:
Kawasaki Genuine M4/M5 Brake & Clutch Lever Fluid (DOT 4) for clutch, or specific gear oil if separate lubrication system (typical for gearbox).
Overall Length:
Approx. 2170 mm (85.4 in)
Overall Width:
Approx. 815 mm (32.1 in)
Overall Height:
Approx. 1250 mm (49.2 in)
Wheelbase:
Approx. 1475 mm (58.1 in)
Ground Clearance:
Approx. 335 mm (13.2 in)
Dry Weight:
Approx. 97 kg (213.8 lbs)
Curb Weight:
Not typically specified for competition motocross bikes, as fluids are added by rider.
Fuel Tank Capacity:
Approx. 8.0 Liters (2.1 US gal)
Crash Test Results:
N/A (Not applicable to off-road competition vehicles)
Braking System:
Hydraulic Disc Brakes (Front & Rear) with larger rotors for improved stopping power in competition.
Suspension Performance:
Adjustable USD (Upside-Down) Front Forks and Monoshock Rear Suspension designed for high-impact absorption and precise control.
Frame Construction:
High-tensile steel perimeter frame for rigidity and strength.
Ergonomics:
Designed for rider control and safety during aggressive riding and jumps.
Oil Change Engine:
Every 5-10 hours of riding, or as specified by manual (typically transmission oil).
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Spark Plug Service:
Every 10-20 hours of riding, inspect and clean or replace.
Chain Adjustment:
Regularly, check for slack and lubrication.
Top End Rebuild:
Variable, depending on riding style and hours, but typically every 20-40 hours for racing, longer for casual use.
Engine Oil Type:
High-quality 2-stroke synthetic oil, mixed with gasoline at 50:1 ratio.
Transmission Oil:
Refer to manual for specific grade (e.g., SAE 80W API GL-4 or GL-5).
Coolant Type:
Permanent type anti-freeze coolant (e.g., 50/50 mix of ethylene glycol and distilled water).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Carburetor Jetting:
Can be sensitive to altitude and temperature, requiring precise jetting for optimal performance.
Power Valve Sticking:
Carbon buildup can cause the power valve to stick, affecting engine response. Regular cleaning is recommended.
Clutch Wear:
High-performance clutches can wear over time, requiring adjustment or replacement based on usage.
Suspension Seals:
Fork and shock seals can be prone to leaks after hard use; regular inspection and maintenance are crucial.
Kawasaki Off Road Legacy:
Kawasaki has a long and successful history in motocross and off-road racing, with the KX line being a cornerstone of their competition lineup for decades.
Kx250 Progression:
The 2003-2005 KX250 represents a significant evolution in the KX250 lineage, building on previous generations with chassis and engine refinements for improved performance and handling.
Manufacturing Location:
Likely Japan, with potential assembly in other regions.
Sales Figures:
Specific sales figures are proprietary, but the KX250 was a strong contender in the highly competitive 250cc motocross market.
