Kawasaki KX250 1982-1991 Workshop Service Manual for Repair

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

27 people are viewing this right now

Tipo: Motorcycle

Proveedor:

SKU: 154004

Etiquetas: 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 Kawasaki KX250 Misc Motorcycle Motorcycles

Variantes de producto

Descripción

This workshop service manual covers the KX250 Motocross Competition motorcycle, produced between 1982 and 1991. The KX250 is renowned for its powerful two-stroke engine, long-travel suspension, and lightweight chassis, making it a formidable machine for competitive off-road racing. Throughout its evolution during this decade, the KX250 consistently pushed the boundaries of motocross technology, offering race-bred design and performance that earned it a significant place in the sport's history. This manual is an essential resource for owners and technicians seeking to understand and maintain this iconic performance dirt bike. This comprehensive 570-page English-language manual provides detailed guidance on all aspects of the KX250. It covers extensive engine and transmission repair, suspension servicing, brake maintenance, electrical system diagnostics, and chassis work. Included are step-by-step procedures for routine maintenance, troubleshooting common issues, and complete rebuilds. Technical specifications, including torque values and clearances, are also provided. The purpose of this manual is to empower owners and mechanics with the knowledge required to effectively maintain, troubleshoot, and repair the KX250, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Model Variant:

Motocross Competition

Product Type:

Workshop Service Manual

Product Format:

👋 Introduction

Market Position

Market Position:

Performance motocross motorcycle for competitive off-road racing

Competitive Analysis

Competitors:

Yamaha YZ250, Honda CR250R, Suzuki RM250

Key Features

Key Features:

Powerful two-stroke engine, long-travel suspension, lightweight chassis, race-bred design

Target Audience

Target Audience:

Motocross racers, off-road enthusiasts, mechanics, and DIY repairers

Manual Value Proposition

Value Proposition:

Essential resource for maintaining, troubleshooting, and repairing the KX250, saving time and money on professional service.

📋 Manual Details

Coverage Areas

Years Covered:

1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991

Page Count

Page Count:

Manual Type

Manual Type:

Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine disassembly, assembly, tuning, and troubleshooting

Transmission:

Gearbox inspection, repair, and adjustment

Suspension:

Front fork (telescopic) and rear shock absorber servicing, tuning, and rebuilds

Brakes:

Front and rear brake system maintenance, bleeding, and component replacement (drum/disc depending on year)

Electrical:

Ignition system, lighting, wiring diagrams, and component testing

Cooling System:

Air-cooled engine specific maintenance

Fuel System:

Carburetor tuning, cleaning, and rebuild; fuel tank and lines

Chassis:

Frame inspection, steering head bearings, and wheel assembly

Bodywork:

Fairing, seat, and plastic component removal/installation

Procedures Included

Maintenance:

Regular service, lubrication, filter changes, spark plug replacement

Troubleshooting:

Diagnostic charts and common problem identification

Repair:

Component level repair and replacement procedures

Rebuild:

Complete engine and gearbox rebuilds

Adjustment:

Clutch, throttle, and brake lever adjustments

Specifications:

Torque values, clearances, and tolerances for all components

Technical Depth

Depth:

Comprehensive from basic maintenance to full engine rebuilds and diagnostics

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Yes (assuming standard PDF creation)

Print Quality

Print Quality:

High resolution, suitable for printing individual pages or the entire manual

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, single-cylinder, reed valve induction

Displacement:

249cc (approximate, varies slightly by year)

Bore X Stroke:

70.0 x 64.0 mm (typical for this era)

Cooling System:

Air-cooled

Compression Ratio:

Approximately 7.8:1 - 8.5:1 (varies by year)

Performance

Horsepower:

Estimated 35-45 HP (varies significantly by year and tuning)

Torque:

Estimated 25-30 lb-ft (varies significantly by year and tuning)

Fuel System

Carburetor:

Mikuni VM Series (e.g., VM28, VM30, VM32 depending on year)

Fuel Type:

Unleaded gasoline with 2-stroke oil mix (e.g., 20:1 or 32:1)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

Lubrication

Lubrication Type:

Premixed fuel/oil

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate

Features

Gear Ratios:

Specific ratios detailed in the manual, optimized for motocross

Final Drive:

Chain drive

📐 Dimensions

Exterior

Frame Type:

Steel semi-double cradle

Suspension Front:

Telescopic forks (e.g., Showa or Kayaba), adjustable damping and preload

Suspension Rear:

Monoshock, Uni-Trak system, adjustable damping and preload

Wheelbase:

Approximately 57.0 - 58.0 inches (varies by year)

Ground Clearance:

Approximately 12.0 - 14.0 inches (varies by year)

Weights

Dry Weight:

Approximately 220 - 235 lbs (varies by year)

Fuel Capacity:

Approximately 2.1 - 2.6 gallons (varies by year)

Wheels Tires

Front Wheel:

21-inch spoke wheel

Rear Wheel:

18-inch spoke wheel

Front Tire Size:

80/100-21 (typical)

Rear Tire Size:

100/90-18 or 110/90-18 (typical)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable for off-road competition motorcycles

Active Features

Braking System:

Front disc brake (from mid-80s onwards), rear drum or disc brake (depending on year)

Passive Features

Handlebar:

Reinforced, high-impact handlebars

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a competition dirt bike; no infotainment features).

Driver Assistance

Driver Assistance Features:

N/A (No electronic driver assistance features).

Connectivity

Connectivity Features:

N/A (No connectivity features).

Performance Enhancements

Power Valve System:

Some models within this range may feature a Kawasaki Integrated Power Valve System (KIPS) for improved low-end and mid-range power delivery.

🔧 Maintenance

Service Intervals

Oil Change:

Frequent oil changes recommended for 2-stroke engines, typically after every few riding sessions or as per manual guidance.

Air Filter Cleaning:

Clean after every few rides, or more frequently in dusty conditions.

Spark Plug Replacement:

Inspect and replace as needed, typically every 10-20 hours of riding.

Top End Rebuild:

Recommended every 40-80 hours of hard riding (piston, rings, cylinder inspection).

Fluid Specifications

Two Stroke Oil:

High-quality synthetic or semi-synthetic 2-stroke racing oil (e.g., Yamalube, Motul, Castrol) mixed with gasoline at specified ratio (e.g., 20:1 or 32:1).

Transmission Oil:

Kawasaki 2-stroke gear oil (e.g., 80W/90 gear oil for gearbox, check manual for specific part number and type).

Fork Oil:

Specific weight fork oil (e.g., 10W, 15W), capacity per leg detailed in manual.

Known Issues

Known Issues:

Common issues include carburetor jetting issues due to altitude/temperature, wear on the clutch plates, and maintenance of the power valve system (on models equipped).

Wear And Tear:

As with any competition bike of this era, expect regular wear on critical components like the piston, rings, bearings, and suspension seals due to hard use.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Kawasaki has a long and successful history in motocross racing, with the KX line being a staple of the sport.

Model Evolution

Model Evolution Overview:

The KX250 underwent continuous development throughout the 1980s, with significant updates in engine performance, suspension technology (e.g., introduction of the Uni-Trak rear suspension), and chassis design.

Production

Production Period:

1982-1991 covers a crucial decade of technological advancement in motocross.

Significance

Significance:

This generation of KX250 was a highly competitive machine, winning numerous races and championships, and is revered by many for its raw power and handling.

🏆 Awards & Recognition

Recognitions

Recognitions:

The KX250 line consistently received praise in period motocross magazines for its performance and competitive edge. Specific awards are difficult to pinpoint without historical data for each model year.

Ratings

Magazine Ratings:

Likely received high performance ratings and often featured in 'Bike of the Year' comparisons within the 250cc motocross class during its production run.

Certifications

Certifications:

N/A (Off-road competition vehicles are not typically certified in the same way as street-legal vehicles).