Product Description Summary:
This is a factory-authorized service manual for the 2011-2012 Kawasaki KX250F motocross bike, providing comprehensive repair and maintenance information essential for owners and technicians.
Value Proposition:
Offers a complete, detailed, and searchable resource to maintain, diagnose, and repair the KX250F, saving time and money compared to dealer-only information.
Manual Highlights:
Includes all factory procedures, torque specifications, part diagrams, troubleshooting guides, and maintenance schedules. Highly searchable and printable.
Primary Coverage:
Comprehensive factory repair and service
Specific Systems Covered:
Engine, Fuel System (Carburetor), Ignition System, Transmission, Drivetrain, Suspension (Front Forks and Rear Shock), Brakes (Front and Rear), Electrical System, Cooling System, Frame, Bodywork, Chassis Components, Lubrication, Maintenance, Troubleshooting, Diagnostics.
Type:
Factory Service Manual / Repair Manual
Engine Mechanical:
Complete engine disassembly, inspection, repair, and reassembly. Includes cylinder head, piston, connecting rod, crankshaft, valves, camshafts, timing, cylinder, and cases.
Fuel And Carburetion:
Detailed procedures for carburetor disassembly, cleaning, inspection, adjustment, and reassembly. Includes jetting information, float bowl adjustment, and troubleshooting fuel delivery issues.
Ignition System:
Covers ignition timing, CDI unit, spark plug specifications, and troubleshooting no-spark conditions.
Transmission And Drivetrain:
Procedures for transmission disassembly, inspection, and reassembly. Covers clutch operation, maintenance, and adjustment, as well as chain and sprocket wear checks and replacement.
Suspension System:
Detailed instructions for front fork (conventional telescopic, Kayaba) and rear shock absorber maintenance, including oil changes, seal replacement, and adjustments. Covers spring rates and damping adjustments.
Brake System:
Front and rear brake system service, including hydraulic brake fluid flush and replacement, caliper inspection and rebuild, pad replacement, and rotor inspection.
Electrical System:
Wiring diagrams, fuse specifications, battery maintenance, lighting system, and troubleshooting electrical faults.
Cooling System:
Radiator and coolant maintenance, including coolant type, capacity, and bleeding procedures.
Chassis And Bodywork:
Frame inspection, wheel bearing maintenance, steering head bearing service, and plastic panel removal/installation.
Maintenance:
Regular scheduled maintenance, including oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning, spark plug replacement, and valve clearance checks.
Troubleshooting:
Comprehensive diagnostic charts and procedures for identifying and resolving common problems such as starting issues, engine performance problems, electrical faults, and suspension noise.
Repair And Rebuild:
Step-by-step instructions for major repairs and complete engine or component rebuilds, including torque specifications for all fasteners.
Diagnostics:
Guidance on interpreting symptoms, checking electrical components, and performing pressure tests or compression tests.
Depth:
Full factory service manual covering complete tear down and rebuild, detailed specifications, and troubleshooting from basic maintenance to complex engine repairs.
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single cylinder
Bore X Stroke:
77.0 x 53.6 mm
Compression Ratio:
13.2:1
Valve Clearance:
Intake: 0.13-0.22 mm, Exhaust: 0.16-0.26 mm (Cold)
Lubrication:
Forced lubrication, wet sump
Horsepower:
Approx. 38-40 HP (estimated at crank, varies by tuning and conditions)
Torque:
Approx. 20-22 lb-ft (estimated at crank, varies by tuning and conditions)
Carburetor Type:
Keihin FCR37 (Flat CR) with Dual-throttle valve system
Fuel Type:
Unleaded gasoline, minimum 91 octane (95 RON recommended)
Fuel Tank Capacity:
1.9 US gallons (7.2 L)
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil
Engine Oil Capacity:
Approx. 0.95 US quarts (0.9 L) without filter change, 1.05 US quarts (1.0 L) with filter change
Transmission Type:
5-speed constant mesh, return shift
Clutch Type:
Wet, multi-disc
Primary Drive:
Spur gear, 3.189 (77/24)
Gear Ratios:
1st: 2.571 (36/14), 2nd: 1.933 (29/15), 3rd: 1.556 (28/18), 4th: 1.333 (24/18), 5th: 1.136 (25/22)
Final Drive:
4.071 (57/14)
Transmission Oil Type:
Use engine oil (same as engine oil specifications)
Transmission Oil Capacity:
1.0 US quarts (0.95 L)
Safety Features Overview:
Motocross bikes are designed for off-road competition and do not feature safety systems like airbags, ABS, or advanced driver-assistance systems found on street vehicles. Safety relies on rider skill and protective gear.
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
Frame Construction:
Strong perimeter frame designed for rigidity and rider feedback.
Infotainment Features:
Not applicable for this motocross model. Focus is on performance and rider interface.
Assistance Features:
Not applicable. Rider skill is the primary control mechanism.
Connectivity Features:
Not applicable. Designed for off-road competition.
Fuel Injection System:
Although this specific manual covers carbureted models, the KX250F line transitioned to fuel injection in later years, representing a significant technological advancement.
Fork Type:
Kayaba Speed Sensitive System (SSS) front forks, a leading technology in motocross suspension for their ability to adapt damping based on wheel speed.
Oil Change Interval:
Every 6-10 hours of hard riding or 15 hours of moderate riding. Check owner's manual for specific recommendations.
Air Filter Cleaning:
After every ride or every 5 hours of riding, depending on conditions. Clean and re-oil.
Chain Maintenance:
Lubricate and check tension before every ride. Adjust/clean as needed.
Valve Clearance Check:
Every 10-15 hours of riding or as recommended in the manual for optimal performance.
Spark Plug Replacement:
Recommended every 15-20 hours of riding or as needed based on inspection.
Coolant Type:
High-quality permanent type coolant (ethylene glycol based), 50/50 mix with distilled water. Kawasaki recommends their own coolant or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, brake pads, tires, chain and sprockets, air filter, and piston rings are common wear items requiring periodic replacement.
Carburetor Performance:
Carburetors can require periodic cleaning and adjustment due to fuel quality and riding conditions. Proper jetting is crucial for optimal performance.
Suspension Maintenance:
Regular fork oil and rear shock oil changes are essential for maintaining suspension performance and longevity.
Kawasaki Motorsports:
Kawasaki has a long and successful history in motorcycle racing, particularly in motocross and supercross, known for producing competitive and innovative machinery.
Kx250F Development:
The KX250F has been a dominant force in the 250cc four-stroke class since its introduction, continuously evolving with technological advancements like fuel injection (introduced earlier), advanced suspension, and chassis refinements.
2011 Updates:
The 2011 model featured revised suspension settings, updated engine tuning for improved low-to-mid range power, and chassis tweaks for better handling and rider ergonomics.
2012 Updates:
The 2012 model further refined suspension damping, updated the ignition timing, and offered minor aesthetic changes, building upon the successful 2011 platform.
