Kawasaki KX250 1992-1993 Full Service Repair Manual

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Stichworte: 1992 1993 Kawasaki KX250 Misc Motorcycle Motorcycles

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Beschreibung

This manual covers the KX250, produced for the 1992 and 1993 model years. The KX250 is a high-performance, liquid-cooled, 2-stroke, single-cylinder off-road motocross competition dirt bike, known for its strong engine, competitive chassis, and focus on power delivery and handling. With a displacement of 249 cc and featuring the Integrated Power Valve System (KIPS), these models were designed to compete at the highest levels of motocross. Its robust construction and engineering quality have made it a respected machine in the off-road racing community. This comprehensive Service Repair Manual provides detailed information for the full service, repair, and maintenance of your KX250. It covers all major systems, including complete engine and transmission overhauls, fuel system tuning and cleaning, ignition system diagnosis, suspension service, brake system maintenance, and electrical system troubleshooting. With step-by-step repair instructions, diagnostic charts, and technical specifications, this manual is an essential resource for owners, mechanics, and technicians seeking to maintain and restore the optimal performance and reliability of their 1992-1993 KX250.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Year:

1992-1993

Codes

Chassis Code 1992:

KX250-K1

Chassis Code 1993:

KX250-K2

👋 Introduction

Market Position

Segment:

Off-road motocross racing, competition dirt bike

Competitive Analysis

Key Competitors:

Honda CR250R, Yamaha YZ250, Suzuki RM250

Key Features

Performance Focus:

Designed for high-performance racing with a focus on power delivery and handling.

Reputation:

Known for its strong engine and competitive chassis for its era.

📋 Manual Details

Coverage Areas

General Coverage:

Full Service Repair and Maintenance

Page Count

Estimated Page Count:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, repair, and reassembly

Transmission:

Gearbox operation, maintenance, clutch service, and rebuild

Fuel System:

Carburetor tuning, cleaning, and overhaul; fuel tank and lines

Ignition System:

CDI system, spark plug diagnosis, and coil testing

Cooling System:

Radiator, hoses, and water pump service (if applicable, though typically air-cooled for this era KX250)

Suspension:

Front fork service (oil changes, seal replacement), rear shock absorber maintenance and adjustment

Brakes:

Front and rear brake system inspection, fluid bleeding, pad replacement, caliper service

Electrical System:

Wiring diagrams, lighting, battery maintenance, troubleshooting electrical faults

Chassis And Bodywork:

Frame inspection, body panel removal and installation, seat maintenance

Wheels And Tires:

Spoke tensioning, wheel bearing service, tire pressure and fitment

Procedures Included

Maintenance:

Scheduled maintenance tasks, lubrication points, general upkeep

Troubleshooting:

Diagnostic charts for common problems and their solutions

Repair:

Step-by-step repair instructions for all major components

Rebuild:

Detailed instructions for engine and transmission rebuilds

Disassembly Reassembly:

Comprehensive guides for taking apart and putting back together all systems

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid changes to full engine and transmission overhauls.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick access to information

Print Quality

Quality:

High-resolution scans ensuring clarity of diagrams and text

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

249 cc (15.2 cu in)

Bore X Stroke 1992:

67.0 mm x 70.0 mm (2.64 in x 2.76 in)

Bore X Stroke 1993:

67.0 mm x 70.0 mm (2.64 in x 2.76 in)

Compression Ratio 1992:

8.8:1 (approx.)

Compression Ratio 1993:

8.8:1 (approx.)

Ports:

Kawasaki Integrated Power Valve System (KIPS)

Performance

Horsepower Approx:

45-50 HP (est.)

Torque Approx:

30-35 lb-ft (est.)

Fuel System

Carburetor Model 1992:

Keihin PWK35 (35mm)

Carburetor Model 1993:

Keihin PWK35 (35mm)

Fuel Type:

Unleaded gasoline (min 91 octane recommended)

Fuel Mix Ratio:

50:1 with high-quality 2-stroke oil (check manual for specific recommendations)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch Type:

Wet, multi-disc, cable-actuated

Features

Gear Ratios:

Specific ratios available in manual, crucial for tuning and performance

Gearbox Oil Spec:

API GL-4, SAE 80W/90 (check manual for specific Kawasaki recommendation)

📐 Dimensions

Exterior

Length Overall 1992:

2170 mm (85.4 in)

Length Overall 1993:

2170 mm (85.4 in)

Width Overall 1992:

810 mm (31.9 in)

Width Overall 1993:

810 mm (31.9 in)

Height Overall 1992:

1250 mm (49.2 in)

Height Overall 1993:

1250 mm (49.2 in)

Wheelbase 1992:

1450 mm (57.1 in)

Wheelbase 1993:

1450 mm (57.1 in)

Ground Clearance 1992:

345 mm (13.6 in)

Ground Clearance 1993:

345 mm (13.6 in)

Weights

Dry Weight 1992:

107 kg (235.9 lbs)

Dry Weight 1993:

107 kg (235.9 lbs)

Fuel Capacity:

8.0 L (2.1 US gal)

Seat Height 1992:

970 mm (38.2 in)

Seat Height 1993:

970 mm (38.2 in)

🛡️ Safety Features

Ratings

Crash Safety:

Not applicable (competition off-road vehicle, no road safety ratings)

Active Features

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Passive Features

Frame Construction:

Strong steel perimeter frame designed for rigidity and impact resistance.

💡 Technology Features

Infotainment

Features:

N/A (Basic competition off-road motorcycle, no infotainment systems)

Driver Assistance

Features:

N/A (No electronic driver assistance features)

Connectivity

Features:

N/A (No connectivity features)

🔧 Maintenance

Service Intervals

Spark Plug Inspection:

Every 10-15 hours of riding or as needed for performance issues.

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions.

Chain Lubrication Adjustment:

Every 5-10 hours of riding, or before long rides.

Coolant Change If Applicable:

If equipped with liquid cooling, typically annually or per manual recommendation.

Fluid Specifications

Fork Oil Type:

Specific weight and type (e.g., SAE 0W-20 or similar) as detailed in the manual. Manual will specify volume per leg.

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific recommendation)

Gearbox Oil Capacity:

Approximately 0.65 L (0.69 US qt) – verify with manual.

Known Issues

Clutch Wear:

As with many high-performance 2-strokes, clutch wear can be accelerated with aggressive riding. Manual provides inspection and replacement procedures.

Carburetor Jetting:

Proper jetting is critical for optimal performance and engine longevity. Manual offers base settings and tuning guidance.

Kips System Maintenance:

The KIPS exhaust port system requires regular cleaning and inspection for proper function. Manual details this procedure.

Suspension Seals:

Fork seals can wear over time, leading to oil leaks. Manual covers seal replacement.

📚 Vehicle History

Brand Heritage

Kawasaki Motocross:

Kawasaki has a long and successful history in motocross racing, with the KX line being a cornerstone.

Model Evolution

Kx250 Progression:

The KX250 received continuous updates throughout the 90s, with the '92-'93 models representing a significant iteration focusing on performance improvements.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motocross Performance:

While specific awards for the '92-'93 models might be varied by publication, the KX250 line consistently competed for top honors in its class during this period.