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Kawasaki KX250F 2004 Service Repair Manual.KX250-N1

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The KX250F, model code KX250-N1, is a distinguished motocross competition machine, first produced in 2004. Engineered for high-revving performance, it features a potent liquid-cooled, four-stroke, 249 cc engine known for...
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Kawasaki KX250F 2004 Service Repair Manual.KX250-N1
The KX250F, model code KX250-N1, is a distinguished motocross competition machine, first produced in 2004. Engineered for high-revving performance, it features a potent liquid-cooled, four-stroke, 249 cc engine known for its strong mid-range and top-end power delivery, complemented by a lightweight aluminum perimeter frame and advanced suspension for exceptional handling and control on the track. The rich motorsports heritage is evident in the KX250F's design, which prioritizes rider input and mechanical feedback, making it a competitive choice in its segment against rivals like the Honda CRF250R and Yamaha YZ250F. This comprehensive service repair manual, written in English, provides detailed guidance for the maintenance and repair of your 2004 KX250F. It covers all essential systems, including complete engine overhauls, carburetor tuning, lubrication, cooling, and starting systems, as well as chassis components like the frame, suspension, wheels, and brakes. The manual offers step-by-step procedures for regular maintenance, component replacement, and troubleshooting, supported by highly detailed exploded diagrams and clear instructions. It is an indispensable resource for owners and technicians to ensure optimal performance and longevity of the vehicle.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX250F
Year:
2004
Codes
Model Code:
KX250-N1
Vin Range 1:
JKAKXMNC4A000001 and up
Vin Range 2:
JKAKX250NNA000001 and up
👋 Introduction
Market Position
Segment:
Motocross Competition
Competitive Analysis
Competitors:
Honda CRF250R, Yamaha YZ250F, Suzuki RM-Z250
Key Features
Engine Design:
High-revving, liquid-cooled, four-stroke single-cylinder. Known for its strong mid-range and top-end power.
Chassis Design:
Lightweight aluminum perimeter frame, advanced suspension components for optimal handling and control.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Page Count
Page Count:
356
Format
File Type:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, tuning, carburetor, ignition, lubrication, cooling, starting systems.
Chassis:
Frame, suspension (front fork, rear shock), steering, wheels, tires, brakes (front and rear).
Electrical:
Wiring diagrams, lighting, ignition system components, troubleshooting electrical faults.
Bodywork:
Fairings, seat, fuel tank, fenders, plastics removal and installation.
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug checks.
Repair:
Detailed step-by-step repair procedures for all major components and systems.
Troubleshooting:
Comprehensive fault finding guides, diagnostic procedures for common and uncommon issues.
Engine Rebuild:
Complete engine disassembly, cleaning, inspection, component replacement (piston, rings, valves, bearings), and reassembly with torque specifications.
Suspension Service:
Fork seal replacement, oil changes, shock absorber service, and adjustment procedures.
Technical Depth
Depth Level:
Comprehensive rebuild and overhaul procedures, advanced diagnostics.
Diagnostic Tools:
Guidance on using standard mechanic's tools for diagnostics and repair, no specialized electronic diagnostic equipment required for core functions.
📊 Manual Specifications
File Format
PDF Quality:
High resolution, clear text and diagrams.
Searchable:
Yes
Print Quality
Diagram Clarity:
Top quality, highly detailed exploded pictures and diagrams.
Instruction Style:
Easy-to-read text sections with step-by-step instructions.
Diagram Type:
Highly detailed exploded pictures and diagrams.
Binding Type
Binding:
Digital (PDF)
Paper Type
Paper:
Not Applicable (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single cylinder
Displacement:
249 cc
Performance
Bore X Stroke:
72.0 x 61.1 mm
Compression Ratio:
12.5:1
Horsepower Estimated:
Approximately 35-40 hp (manufacturer does not publish official figures for competition bikes).
Torque Estimated:
Approximately 20-23 lb-ft (manufacturer does not publish official figures for competition bikes).
Fuel System
Carburetor:
Keihin FCR37 with hot start button
Fuel Type:
Unleaded gasoline, octane rating 91 or higher
Lubrication
Oil Type:
SAE 10W-40 motorcycle oil (JASO MA certified)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Clutch:
Wet, multi-disc, cable operated
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Overall Length:
2185 mm (86.0 in)
Overall Width:
800 mm (31.5 in)
Overall Height:
1270 mm (50.0 in)
Wheelbase:
1480 mm (58.3 in)
Ground Clearance:
335 mm (13.2 in)
Seat Height:
965 mm (38.0 in)
Weights
Curb Weight:
106 kg (233.7 lbs)
Fuel Tank Capacity:
7.0 L (1.8 US gal)
Front Tire Size:
80/100-21 51M
Rear Tire Size:
100/90-19 57M
🛡️ Safety Features
Ratings
Safety Features:
Motocross bikes typically do not have standardized safety ratings like street vehicles. Focus is on performance and rider control.
Active Features
Braking System:
Hydraulic disc brakes front and rear for strong stopping power.
Passive Features
Frame Design:
Strong and rigid aluminum frame designed for stability and responsive handling.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Competition Motocross Bike)
Driver Assistance
Electronic Aids:
N/A (Focus on rider input and mechanical feedback)
Connectivity
Connectivity Features:
N/A (Competition Motocross Bike)
Engine Technology
Ignition System:
Digital CDI
Chassis Technology
Suspension Front:
47mm inverted cartridge fork with 20-way compression and 18-way rebound damping, 11.8 inches (300 mm) of wheel travel.
Suspension Rear:
New Uni-Trak with gas-oil unit, spring preload, 17-way positive-stop compression and 16-way rebound damping, 12.4 inches (315 mm) of wheel travel.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 15 hours of operation or as needed based on riding conditions.
Air Filter Cleaning:
Every 5 hours of operation or more frequently in dusty conditions.
Spark Plug Inspection:
Every 20 hours of operation.
Chain Lubrication Inspection:
Every 20 hours of operation or as needed.
Valve Clearance Check:
Every 30 hours of operation.
Fluid Specifications
Engine Oil Capacity:
1.0 L (1.05 US qt) without filter change; 1.1 L (1.16 US qt) with filter change.
Coolant Type:
Permanent type antifreeze coolant (50% solution with distilled water).
Known Issues
Common Wear Items:
Clutch plates, piston rings, valve seats due to high performance demands. Suspension seals and fork oil are also critical maintenance points.
Carburetor Tuning:
Carburetor jetting may need adjustment based on altitude, temperature, and modifications for optimal performance.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsport:
Kawasaki has a long and successful history in off-road and motocross racing, establishing a reputation for performance and durability.
Model Evolution
Kx250F Lineage:
The KX250F was introduced as Kawasaki's competitive four-stroke motocross offering, evolving through technology updates in engine management, suspension, and chassis design.
Production
Manufacturing Origin:
Japan
🏆 Awards & Recognition
Recognitions
Motocross Awards:
Kawasaki KX models have historically been strong contenders and winners in various professional motocross championships, reflecting their performance capabilities.
Ratings
Industry Reviews:
Critically acclaimed for its powerful engine and agile handling by motocross publications.
Certifications
Certifications:
N/A (Competition Use Only)
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