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Kawasaki KX250 2006 Service Repair Manual Pdf

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The 2006 Kawasaki KX250 is a high-performance, 2-stroke, liquid-cooled, single-cylinder motocross motorcycle engineered for off-road racing and aggressive recreational riding. Building on Kawasaki's strong legacy in motocross, this model is...
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SKU: 142475
Kawasaki KX250 2006 Service Repair Manual Pdf
The 2006 Kawasaki KX250 is a high-performance, 2-stroke, liquid-cooled, single-cylinder motocross motorcycle engineered for off-road racing and aggressive recreational riding. Building on Kawasaki's strong legacy in motocross, this model is known for its potent 249 cc engine and advanced suspension design, featuring USD front forks and Uni-Trak rear suspension for superior handling and adjustability. Its robust perimeter frame provides stability, and hydraulic disc brakes offer effective stopping power, making it a competitive machine in its class, often compared to other leading motocross bikes of its era. This service repair manual provides comprehensive, dealership-level coverage for the 2006 Kawasaki KX250. It details essential maintenance procedures, including oil changes, filter cleaning, and chain adjustments, alongside in-depth engine rebuild instructions for the 2-stroke powerplant. The manual covers the fuel, ignition, cooling, exhaust, chassis, suspension, brake, wheel, and electrical systems, offering troubleshooting guides and diagnostic capabilities for common issues. With its clear, step-by-step instructions and diagrams, this English-language manual empowers owners and technicians to maintain, repair, and optimize the performance and longevity of their KX250.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX250
Year:
2006
Vehicle Type:
Motocross Motorcycle
Codes
Engine Code:
Likely a specific K-code engine variant, but not explicitly provided in product info.
👋 Introduction
Market Position
Motorcycle Segment:
High-performance motocross competition motorcycle.
Competitive Analysis
Key Competitors Era:
Yamaha YZ250, Honda CR250R, Suzuki RM250.
Key Features
Engine Type:
2-stroke, liquid-cooled, single-cylinder.
Suspension Design:
Advanced USD front forks and Uni-Trak rear suspension for superior handling and adjustability.
Intended Use:
Off-road racing and aggressive recreational riding.
Value Proposition
Diy Repair Benefit:
Enables cost savings by empowering owners to perform maintenance and repairs themselves.
Ease Of Use:
Features easy-to-follow, step-by-step instructions with numerous pictures and diagrams.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service, repair, and diagnosis for the 2006 Kawasaki KX250.
Page Count
Page Count:
Not explicitly stated, but service manuals of this era are typically several hundred pages.
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine System:
Detailed coverage of the 2-stroke engine, including disassembly, inspection, assembly, and tuning.
Fuel System:
Covers carburetor settings, fuel delivery, and throttle body operation.
Ignition System:
Includes spark plug specifications, ignition timing, and CDI unit information.
Cooling System:
Details of the liquid cooling system, including radiator, water pump, and coolant specifications.
Exhaust System:
Information on the expansion chamber, muffler, and any associated components.
Chassis System:
Covers frame, swingarm, linkages, and mounting points.
Suspension System:
Front fork (e.g., USD cartridge forks) and rear shock absorber (e.g., Uni-Trak) adjustments, service, and specifications.
Brake System:
Front and rear disc brake system service, fluid specifications, and pad replacement.
Wheel And Tire System:
Wheel bearing service, tire pressure recommendations, and spoke tension.
Electrical System:
Wiring diagrams, lighting, battery maintenance, and fuse specifications.
Emission Control:
Information related to emission control components and their service, if applicable to the model.
Procedures Included
Periodic Maintenance:
Scheduled maintenance tasks, including oil changes, filter replacements, chain adjustment, and general inspections.
Troubleshooting:
Diagnostic procedures for common problems and fault finding.
Engine Rebuild:
Step-by-step instructions for complete engine disassembly, rebuilding, and reassembly.
Suspension Service:
Front fork oil changes, seal replacement, and rear shock servicing.
Brake System Service:
Bleeding procedures, caliper service, and master cylinder maintenance.
Electrical Diagnostics:
Troubleshooting electrical circuits and components.
Cleaning And Lubrication:
Guidelines for cleaning the motorcycle and lubricating moving parts.
Technical Depth
Depth Level:
Professional Dealership Level - detailed enough for certified technicians.
Diagnostic Capability:
Advanced diagnostics for engine performance, electrical faults, and fuel system issues.
Repair Scope:
Covers everything from routine maintenance to complete component overhauls and engine rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchable:
Typically yes, if the PDF is generated from OCR or native text.
Print Quality
Printability:
All pages are printable.
Binding Type
Binding:
Not applicable for digital PDF download.
Paper Type
Paper Type:
Not applicable for digital PDF download.
⚙️ Engine Specifications
Primary Engine
Engine Configuration:
2-stroke, Liquid-Cooled, Single-Cylinder
Displacement:
249 cc
Bore X Stroke:
Not explicitly stated, but typical for a 250cc 2-stroke of this era.
Compression Ratio:
Not explicitly stated.
Carburetor:
Likely a Keihin PWK carburetor (e.g., 38mm), but specific model not detailed in product info.
Ignition:
Digital CDI (Capacitor Discharge Ignition)
Lubrication:
Premix (Fuel/Oil) and separate transmission oil.
Performance
Horsepower:
Typically in the range of 45-50 HP, but exact figures not provided.
Torque:
Not explicitly stated.
Fuel System
Fuel Type:
Unleaded gasoline with 2-stroke oil mix.
Fuel Tank Capacity:
Likely around 7-8 liters (approx. 1.8-2.1 gallons).
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh, sequential manual.
Optional
Optional Transmission:
None for this model.
Features
Clutch Type:
Wet multi-plate manual clutch.
Gear Ratios:
Specific ratios not provided in product info, but detailed in the manual.
Final Drive:
Chain drive.
📐 Dimensions
Exterior
Overall Length:
Not explicitly stated, but typical for a 250cc motocross bike.
Overall Width:
Not explicitly stated.
Overall Height:
Not explicitly stated.
Wheelbase:
Not explicitly stated, but typically around 57-59 inches.
Ground Clearance:
Not explicitly stated, but designed for high clearance.
Weights
Dry Weight:
Around 210-215 lbs (95-98 kg), but exact figure not provided.
Wet Weight:
Not explicitly stated.
🛡️ Safety Features
Ratings
Safety Certifications:
Not applicable for off-road competition motorcycles in the same way as street vehicles.
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Passive Features
Frame Construction:
Strong and rigid perimeter frame for stability and rider control.
💡 Technology Features
Infotainment
Infotainment Features:
N/A - Motocross bike designed for performance, not comfort or entertainment features.
Driver Assistance
Driver Assistance Systems:
N/A - No electronic rider aids typically found on this type of motorcycle.
Connectivity
Connectivity Options:
N/A - No onboard electronics for connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10-15 hours of riding, or as specified in the manual.
Air Filter Cleaning:
Frequent cleaning and re-oiling recommended, often after every few rides or in dusty conditions.
Chain Lubrication Adjustment:
Regularly, typically every 5-10 hours of riding, depending on conditions.
Top End Rebuild:
Recommended every 30-50 hours of riding, depending on usage intensity.
Fluid Specifications
Transmission Oil:
Kawasaki specifies specific gear oil for the transmission, e.g., SAE 80W-90.
Coolant Type:
High-quality ethylene glycol-based antifreeze coolant, usually a 50/50 mix with distilled water.
Brake Fluid:
DOT 4 hydraulic brake fluid.
2 Stroke Oil:
High-quality 2-stroke racing oil recommended for pre-mix (e.g., castor-based or synthetic).
Known Issues
Common Wear Items:
Clutch plates, piston rings, top-end bearings, fork seals, chain and sprockets.
Performance Tuning Considerations:
Jetting adjustments for carburetor are critical for optimal performance and engine longevity.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Legacy:
Kawasaki has a long and successful history in motocross racing, with the KX line being a dominant force for decades.
Model Evolution
Kx Series Development:
The KX250 has undergone continuous development, with significant chassis and engine updates throughout its production run.
Production
Kx250 Production Years:
The KX250 (2-stroke) was produced for many years, with significant updates in 2005-2007 that are highly regarded.
🏆 Awards & Recognition
Recognitions
Motocross Performance Awards:
The KX250 model line has consistently been recognized for its strong performance and competitive edge in motocross racing throughout its history.
Ratings
Industry Reviews:
Well-received by motocross publications and riders for its potent engine and capable chassis during its production era.
Certifications
Emission Compliance Certification:
N/A - Competition off-road motorcycles are generally not subject to the same emission regulations as street-legal vehicles.
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