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Kawasaki KX250F Service Manual Repair 2006-2008 KX 250F

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The Kawasaki KX250F is a highly regarded four-stroke motocross bike, renowned for its potent engine, agile handling, and competitive performance in the high-performance motocross racing segment. Produced for the 2006,...
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Art.-Nr: 129691
Kawasaki KX250F Service Manual Repair 2006-2008 KX 250F
The Kawasaki KX250F is a highly regarded four-stroke motocross bike, renowned for its potent engine, agile handling, and competitive performance in the high-performance motocross racing segment. Produced for the 2006, 2007, and 2008 model years, this machine has a rich heritage in motocross, consistently proving itself a dominant force in championships. Its engineering focuses on delivering maximum power and responsiveness, making it a favored choice for both professional racers and serious enthusiasts seeking peak performance on the track. This comprehensive 391-page factory service manual provides essential repair and maintenance information for the 2006-2008 Kawasaki KX250F. It covers all major systems, including detailed procedures for engine tear-down and rebuild, transmission, clutch, chassis components, suspension, brakes, and electrical systems. The manual also includes routine maintenance schedules, troubleshooting guides, and precise technical specifications, making it an invaluable resource for owners and technicians aiming to maintain, repair, and optimize the performance and longevity of this exceptional motocross motorcycle.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX250F
Model Variant:
Four-Stroke Motocross Bike
Generation
Production Years Covered:
2006, 2007, 2008
Codes
Engine Code Range:
Likely varies by specific model year, but generally identified by chassis/engine serial numbers.
👋 Introduction
Market Position
Market Segment:
High-performance motocross racing segment.
Competitive Analysis
Key Competitors:
Honda CRF250R, Yamaha YZ250F, KTM 250 SX-F.
Key Features
Vehicle Appeal:
Renowned for its potent four-stroke engine, agile handling, and competitive performance in its class.
Manual Value Proposition
Value To Owner:
Essential resource for maintaining and repairing the KX250F, enabling owners to perform their own service, diagnose issues, and ensure optimal performance, saving time and money on professional labor.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive repair and service information for the 2006-2008 Kawasaki KX250F.
Page Count
Page Count:
391 pages
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine tear down and rebuild, internal components (piston, connecting rod, crankshaft, cylinder head, valves, cams), lubrication, cooling system, fuel system (carburetor, fuel pump).
Drivetrain Systems:
Transmission, clutch, primary reduction gear, gearshift mechanism, swingarm, rear suspension linkage.
Chassis Systems:
Frame, front forks (suspension), rear shock absorber, brakes (front and rear), wheels, tires, steering system, triple clamps.
Electrical Systems:
Ignition system, charging system (stator, flywheel, rectifier), battery, lighting (if applicable to model variant), starter system (kickstart).
Bodywork And Controls:
Body panels, plastics, seat, handlebars, throttle cable, brake levers/pedals, footpegs.
Procedures Included
Maintenance Procedures:
Routine maintenance schedules, oil changes, filter replacements, chain adjustment, lubrication points, valve clearance adjustment, coolant changes.
Repair Procedures:
Complete engine overhaul, transmission rebuild, suspension service, brake system repair, carburetor tuning and rebuilding, electrical component testing and replacement.
Troubleshooting Guides:
Diagnostic procedures for common problems (e.g., no spark, starting issues, performance problems), symptom-based troubleshooting, error code identification (if applicable).
Installation Procedures:
Instructions for installing specific components or performing upgrades (implied by 'complete tear down and rebuild').
Technical Depth
Technical Depth:
Highly detailed, suitable for professional mechanics and experienced DIY enthusiasts. Includes precise torque specifications, measurements, and assembly sequences for complete rebuilds.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable and savable with no restrictions.
Binding Type
Binding Type:
Digital download - N/A (can be printed and bound by user)
Paper Type
Paper Type:
Digital download - N/A (PDF format)
Features
Navigability:
Clickable chapters and searchable text for easy information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single-cylinder
Engine Displacement:
249cc (249 cubic centimeters)
Bore X Stroke:
72.0 x 61.1 mm (typical for this generation)
Compression Ratio:
12.5:1 (typical for this generation)
Performance
Horsepower:
Approximately 37-40 HP at peak RPM (specific figures vary by year and dyno testing).
Torque:
Specific torque figures not readily available in general product info, but the manual will contain exact specifications.
Fuel System
Carburetor Type:
Keihin FCR39 (Flat CR Special) with accelerator pump, digital fuel injection (DFI) was introduced later in this model's lifecycle for some variants or aftermarket upgrades, but factory spec for 2006-2008 is typically carburetor.
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 2.1 gallons (7.9 liters) - specific figures in manual.
Lubrication
Engine Oil Type:
Motorcycle-specific 4-stroke engine oil, SAE 10W-40 viscosity recommended. Manual will specify exact API service classification (e.g., SG or higher).
Engine Oil Capacity:
Approximately 1.2 quarts (1.1 liters) without filter change, 1.3 quarts (1.2 liters) with filter change. Precise capacities listed in manual.
🔧 Transmission
Standard
Transmission Type:
Constant-mesh, 5-speed
Clutch Type:
Wet, multi-disc
Features
Gear Ratios:
Specific gear ratios will be detailed within the manual for each gear.
📐 Dimensions
Exterior
Overall Length:
Approximately 85.0 inches (2159 mm) - specific figures vary by year.
Overall Width:
Approximately 32.1 inches (815 mm) - specific figures vary by year.
Overall Height:
Approximately 49.4 inches (1255 mm) - specific figures vary by year.
Weights
Dry Weight:
Approximately 216.1 lbs (98 kg) - specific figures vary by year.
Curb Weight:
Not typically quoted for motocross bikes as it includes fluids and rider.
Seat Height:
Approximately 37.9 inches (963 mm) - specific figures vary by year.
Ground Clearance:
Approximately 13.2 inches (335 mm) - specific figures vary by year.
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable for off-road competition motorcycles which are not subject to road safety regulations or crash testing.
Active Features
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
Passive Features
Frame Construction:
Lightweight and rigid perimeter frame designed for optimal rigidity and handling.
💡 Technology Features
Infotainment
Infotainment Features:
None (off-road competition motorcycle).
Driver Assistance
Driver Assistance Systems:
None (off-road competition motorcycle).
Connectivity
Connectivity Features:
None (off-road competition motorcycle).
Engine Management
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.
Fuel System Technology:
Carbureted with accelerator pump and jetting specifications provided in the manual. Some later models or aftermarket conversions might feature EFI.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 5-10 hours of riding, or after significant racing events. Manual will provide precise recommendations based on operating conditions.
Air Filter Cleaning:
Recommended every 2-5 hours of riding, depending on dust conditions. Detailed cleaning and oiling procedure in manual.
Valve Clearance Check:
Typically every 10-20 hours of riding. Critical for maintaining engine performance. Manual will specify tolerances and adjustment procedures.
Fluid Specifications
Coolant Type:
High-quality, permanent type ethylene glycol based coolant, pre-diluted with de-mineralized water. Manual will specify correct mixture ratio and capacity.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Manual will specify bleeding procedures and recommended fluid brands if applicable.
Known Issues
Common Wear Items:
Clutch plates, piston rings, valve stem seals, wheel bearings, fork seals, chain and sprockets are common wear items on motocross bikes. Manual will detail inspection and replacement procedures.
Engine Longevity:
Proper and regular maintenance, as detailed in the manual, is crucial for maximizing engine life and preventing premature wear.
📚 Vehicle History
Brand Heritage
Kawasaki Motocross History:
Kawasaki has a long and successful history in motocross racing, with the KX line being a dominant force for decades.
Model Evolution
Kx250F Development:
The KX250F underwent significant development during the mid-2000s, transitioning to four-stroke technology and incorporating advanced chassis and engine designs to compete at the highest level.
Production
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Motocross Contributions:
The KX250F model line has consistently been a top contender in AMA Supercross and Motocross championships, earning numerous race wins and titles throughout its production years.
Ratings
Rider Reviews:
Generally praised for its powerful engine and responsive handling, often cited as a favorite among professional and amateur racers.
Certifications
Manufacturing Standards:
Manufactured to Kawasaki's high-quality standards for performance and durability in demanding off-road conditions.
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