Segment:
High-performance two-stroke motocross motorcycle.
Target User:
Motocross racers, off-road enthusiasts, mechanics.
Competitors 2005:
Yamaha YZ250, Suzuki RM250, Honda CR250R.
Engine Type:
Liquid-cooled, 2-stroke, single cylinder.
Frame Type:
Perimeter aluminum frame.
Value Proposition:
Essential resource for maintaining and repairing the 2005 Kawasaki KX250, enabling owners to perform complex tasks and optimize performance.
Covered Systems:
General Maintenance, Fuel System, Cooling System, Engine Top End, Right Engine Side, Engine Removal/Installation, Engine Bottom End/Transmission, Wheels/Tires, Shaft Drive (partial inclusion, potentially referring to final drive system)
Estimated Pages:
Likely 300-500 pages, typical for a full workshop manual
Type:
Workshop Manual / Service Manual
Language:
German ('Motorrad Werkstatt-Handbuch')
Format:
Physical Book (implied by context of sales business)
Engine Assembly:
Detailed coverage of top end (cylinder, piston, head), right side components (clutch, gearbox input shaft), and bottom end (crankshaft, connecting rod, gearbox output shaft, shifting mechanism).
Fuel System:
Includes carburetor service, fuel lines, and potentially fuel tank maintenance.
Cooling System:
Covers radiator, coolant hoses, water pump, and fluid maintenance.
Drivetrain:
Details on transmission operation, gear shifting, and final drive (shaft drive, if applicable, though KX250 is typically chain drive - this might be a generic term or specific to a variant).
Wheels Tires:
Covers wheel bearing maintenance, tire removal/installation, and potentially spoke tensioning.
Chassis Suspension:
Implied coverage for aspects related to wheel and tire servicing, may touch on fork and shock absorber maintenance if integrated with wheel removal.
Maintenance:
Routine service checks, lubrication, filter replacements, fluid changes.
Troubleshooting:
Diagnostic information for common issues within covered systems, likely including flowcharts or symptom-based guides.
Repair Rebuild:
Detailed disassembly and reassembly procedures for engine components, transmission, and potentially other areas.
Component Removal Installation:
Step-by-step instructions for removing and installing major components like the engine, wheels, and carburetor.
Depth:
Comprehensive, covering routine maintenance to major mechanical repairs and engine rebuilds.
Diagnostic Level:
Includes specific diagnostic information for engine performance and mechanical issues.
Specifications Data:
Likely includes torque specifications, clearances, fluid capacities, and other critical data.
Quality:
Assumed to be professional, likely with clear diagrams and text.
Binding:
Likely perfect bound or spiral bound for durability in a workshop environment.
Paper Type:
Standard quality paper suitable for a workshop manual, possibly with glossy pages for diagrams.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder, Reed valve induction
Bore X Stroke:
66.4 mm x 72.0 mm
Compression Ratio:
9.9:1 (typical for this era)
Carburetor:
Keihin PWK39 (common for this model)
Lubrication:
Premix or separate oil injection (likely premix for racing focus)
Horsepower:
Approx. 47-50 HP (peak, at crankshaft)
Torque:
Approx. 30-32 lb-ft (peak, at crankshaft)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Capacity:
Approx. 8.5 Liters (2.2 US Gallons)
Type:
5-speed constant mesh
Clutch:
Wet, multi-disc, cable-actuated
Gear Ratios:
Specific ratios would be detailed in the manual, e.g., 1st: 2.46, 2nd: 1.75, 3rd: 1.33, 4th: 1.09, 5th: 0.92 (example ratios for a similar model)
Final Drive:
O-ring sealed chain drive
Transmission Fluid:
Kawasaki Motorcycle Gear Oil SAE 80W-90 (or equivalent, as specified in manual)
Length:
Approx. 2,160 mm (85.0 in)
Width:
Approx. 820 mm (32.3 in)
Height:
Approx. 1,250 mm (49.2 in)
Wheelbase:
Approx. 1,475 mm (58.1 in)
Ground Clearance:
Approx. 350 mm (13.8 in)
Dry Weight:
Approx. 97 kg (214 lbs)
Curb Weight:
Approx. 103 kg (227 lbs) (with fluids)
Safety Certifications:
Designed for closed-course competition use; not street legal.
Braking System:
Hydraulic disc brakes front and rear. Front: Dual piston caliper, 250mm disc. Rear: Single piston caliper, 240mm disc.
Chassis Design:
Strong aluminum perimeter frame for stability and rider feedback.
Suspension Components:
High-performance suspension, though specific safety features are not applicable in the typical automotive sense.
Oil Change:
Every 10-15 hours of riding or annually (engine oil).
Air Filter Cleaning:
Every 5-10 hours of riding, depending on conditions.
Spark Plug Replacement:
Every 20-30 hours of riding (specific plug type, e.g., NGK BR9EG).
Top End Rebuild:
Recommended every 40-60 hours of hard riding (piston, rings).
Coolant:
High-quality ethylene glycol-based coolant, 50/50 mix with distilled water. Capacity approx. 1.0L.
Brake Fluid:
DOT 4 hydraulic brake fluid.
2 Stroke Oil:
High-quality synthetic 2-stroke racing oil, mixed with fuel at a ratio specified in the manual (e.g., 32:1 or 40:1).
Common Wear Items:
Clutch plates, piston rings, spokes, wheel bearings, chain and sprockets, radiators.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes; requires proper jetting for optimal performance.
Engine Heat:
Like most powerful 2-strokes, proper cooling system maintenance is crucial to prevent overheating.
Kawasaki Motorcycle Legacy:
Kawasaki has a long and successful history in motocross, particularly with the KX line, known for powerful two-stroke engines and competitive chassis.
Kx250 Evolution:
The KX250 underwent significant updates throughout the 2000s, with the 2005 model being part of a generation that focused on chassis stiffness, engine tuning, and improved suspension components.
Production Era:
The KX250 two-stroke was produced for many years, with the 250cc two-stroke era in motocross peaking around this time before the shift to four-strokes.
Manufacturing Location:
Typically manufactured in Japan, though assembly may occur in other regions.
Motocross Championships:
Kawasaki KX models have a history of winning championships across various racing series, contributing to the model's reputation.
Motorcycle Journal Reviews:
Contemporary reviews often praised the KX250's strong engine power, agile handling, and competitive chassis, though it competed in a very strong field.
