Segment:
High-performance motocross competition motorcycle
Target Audience:
Motocross racers, off-road enthusiasts, mechanics, restorers
Key Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, KTM 250 EXC
Vehicle Strengths:
Strong powerband, capable suspension, reliable construction for its era
Manual Value Proposition:
Essential resource for maintaining peak performance and longevity of the KX250
Primary Focus:
Service, Repair, Maintenance, Troubleshooting, Overhaul
Scope:
Complete workshop procedures for all aspects of the vehicle
Estimated Page Count:
400-600 pages (typical for comprehensive factory manuals of this era)
Type:
Factory Service Manual / Workshop Manual
Format:
Digital Download (PDF or similar compatible format)
Accessibility:
Instant Downloadable to Computer, Tablet, or Smartphone
License:
No Extra Fees, No Expiry Dates
Engine Assembly:
Complete disassembly, inspection, repair, and reassembly of the 2-stroke engine
Cooling System:
Radiator, hoses, thermostat, coolant specifications and servicing
Fuel System:
Carburetor disassembly, cleaning, adjustment, jetting information, fuel pump (if applicable)
Ignition System:
CDI unit, spark plug specifications, ignition timing, coil testing
Exhaust System:
Expansion chamber, muffler maintenance and inspection
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, final drive chain and sprockets
Suspension Front:
Telescopic fork service, oil levels, damping adjustments, seal replacement
Suspension Rear:
Monoshock system, linkage maintenance, shock absorber servicing, spring preloads
Brakes Front:
Hydraulic disc brake system, caliper overhaul, pad replacement, fluid specifications, bleeding procedures
Brakes Rear:
Hydraulic disc brake system, caliper overhaul, pad replacement, fluid specifications, bleeding procedures
Wheels Tires:
Spoke tensioning, wheel bearing service, tire pressure recommendations, rim specifications
Electrical System:
Lighting (if equipped), wiring diagrams, battery maintenance (if applicable), kill switch operation
Frame Chassis:
Frame inspection, subframe maintenance, steering head bearing service
Bodywork:
Plastic panel removal and installation, seat, fuel tank, fenders
Routine Maintenance:
Oil changes (premix ratios), filter cleaning/replacement, chain adjustment, spark plug inspection
Troubleshooting:
Diagnosis of common running issues, electrical faults, starting problems
Rebuilding:
Engine rebuild procedures, including piston, rings, crankshaft, and cylinder porting specifications
Adjustments:
Carburetor tuning, clutch lever adjustment, suspension clicker settings
Special Tools:
Identification and usage of necessary specialized tools for specific tasks
Torque Specifications:
Precise torque values for all critical fasteners
Wiring Diagrams:
Comprehensive electrical schematics for model year variations
Depth:
Comprehensive: from basic checks to full engine and chassis overhauls
Diagnostic Capabilities:
Detailed fault finding guides and symptom-based troubleshooting trees
Part Replacement:
Step-by-step instructions for replacing all major and minor components
Engine Type:
2-Stroke, Liquid-Cooled, Single Cylinder
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
68.5 mm x 67.5 mm (Typical for this generation)
Compression Ratio:
8.5:1 to 9.5:1 (Variable by model year, consult manual for exact spec)
Horsepower:
Approx. 45-50 HP (Estimate, actual figures vary by year and tune)
Torque:
Approx. 28-30 lb-ft (Estimate, actual figures vary by year and tune)
Carburetor Type:
Keihin PWK (Typical, e.g., PWK38)
Fuel Type:
Unleaded Gasoline (91 Octane or higher recommended), mixed with 2-stroke oil
Premix Ratio:
50:1 or 32:1 (Consult manual and oil manufacturer recommendations)
Reed Valve System:
Yes, typically with carbon fiber reeds
Power Valves:
Kawasaki Integrated Power Valve System (KIPS)
Overall Length:
Approx. 85.2 inches (2165 mm) (Varies slightly by year)
Overall Width:
Approx. 31.7 inches (805 mm) (Varies slightly by year)
Overall Height:
Approx. 49.4 inches (1255 mm) (Varies slightly by year)
Wheelbase:
Approx. 57.9 inches (1470 mm) (Varies slightly by year)
Ground Clearance:
Approx. 13.4 inches (340 mm) (Varies slightly by year)
Dry Weight:
Approx. 219.4 lbs (99.5 kg) (Varies slightly by year)
Wet Weight:
Not typically published, but significantly higher than dry weight
Cargo Capacity:
N/A (Competition Motocross Motorcycle)
Spark Plug Inspection:
Every 10-15 hours of operation
Air Filter Cleaning:
After every ride, or more frequently in dusty conditions
Chain Lubrication Adjustment:
Every 5-10 hours of operation, or as needed
Suspension Service:
Fork oil change every 20-30 hours, full suspension rebuild as needed based on wear
Top End Rebuild:
Every 40-60 hours of operation for competition use, longer for recreational use
Engine Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil
Transmission Oil Type:
API GL-4 SAE 80 or 90 Hypoid Gear Oil (Check manual for exact specification)
Coolant Type:
Permanent type ethylene glycol-based coolant (50% solution with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 Brake Fluid (Check manual for specific recommendation)
Common Wear Items:
Piston rings, clutch plates, wheel bearings, steering head bearings, fork seals
Common Engine Problems:
Carburetor jetting issues due to altitude/temperature changes, KIPS valve sticking if not maintained
Brand History:
Kawasaki has a long-standing legacy in motorcycle racing, particularly in motocross, known for powerful and innovative machines.
Kx250 Evolution 90S:
The KX250 underwent significant updates throughout the 1990s, including chassis refinements, engine tuning (KIPS system improvements), and suspension advancements, making the 1992-1995 models a key period of development.
Manufacturing Location:
Japan (Primary)
Significance:
This generation of KX250 was a competitive machine in AMA Supercross and Motocross championships.
