Segment:
Motocross / Off-Road Competition
Competitors:
Honda CR250R, Yamaha YZ250, Suzuki RM250
Vehicle Focus:
Performance-oriented motocross bike, known for its strong powerband and agile handling.
Manual Advantage:
Provides essential information for owners and mechanics to maintain and repair the specific KX250 models, offering an alternative to expensive official print manuals.
Usability:
Instant access allows for immediate troubleshooting and repair, especially useful in remote locations or for on-the-fly fixes.
Primary Coverage:
2005-2008 Kawasaki KX250 2-Stroke Motorcycles
Specific Models Covered:
2005 Kawasaki KX250, 2006 Kawasaki KX250, 2007 Kawasaki KX250, 2008 Kawasaki KX250
Estimated Page Count:
N/A (Digital Download - Content extensive)
Type:
Repair Manual / Workshop Manual / Owner's Manual / Parts Catalog Information
Format:
PDF (Electronic Download)
Engine:
Complete engine assembly, disassembly, diagnosis, internal components (piston, rings, crankshaft, connecting rod, cylinder, head, reed valve assembly)
Fuel System:
Carburetor (Mikuni VM series commonly used for this era), fuel tank, fuel lines, fuel filter
Lubrication Cooling:
2-stroke oil injection system (if equipped, though many KX models rely on pre-mix), cooling system (radiators, hoses, coolant)
Transmission Drivetrain:
Clutch operation, transmission gears, shift drum and forks, drive chain, sprockets (front and rear)
Steering Suspension:
Handlebar, steering stem, bearings, front fork (Öhlins, Showa, KYB depending on specific model year and configuration), rear shock absorber (monoshock system)
Brakes:
Front and rear hydraulic disc brake systems, brake fluid, calipers, master cylinders, lines, pads, rotors
Electrical System:
Ignition system (CDI, coil), lighting (if equipped), wiring diagrams, battery, fuses, switches, kill switch
Bodywork Frame:
Frame, sub-frame, fenders, seat, fuel tank (plastic), airbox, exhaust system (expansion chamber, silencer)
Maintenance:
Routine checks, oil changes (gearbox oil), filter cleaning/replacement, chain adjustment, spark plug inspection/replacement, pre-ride inspections
Repair:
Engine rebuilds, carburetor tuning, suspension servicing, brake bleeding, clutch adjustment, electrical diagnostics and repair, wheel bearing replacement
Troubleshooting:
Diagnosis of common running issues, electrical faults, engine performance problems, suspension anomalies
Installation Removal:
Engine removal and installation, wheel removal and installation, exhaust system removal and installation, body panel removal and installation
Depth:
Comprehensive (from basic maintenance to complete engine disassembly and overhaul)
Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement Cc:
249cc (approximately, common for KX250 2-stroke)
Bore X Stroke:
Specifications vary slightly by year; typically around 66.4mm x 72mm.
Horsepower:
Typically in the range of 45-50 HP, depending on year and tuning.
Torque:
Significant torque for its displacement, optimized for mid-range power delivery.
Carburetor Type:
Mikuni TMX series (e.g., TMX38) is common for this generation.
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix (typically 32:1 or 40:1, check specific manual recommendations).
Ignition System:
Digital CDI with electronic advance
Starting System:
Kickstarter
Oil Change Gearbox:
Every 15-20 hours of riding or annually. Specific Kawasaki gearbox oil grades (e.g., SAE 80 or 90 GL-4) are recommended.
Air Filter Cleaning:
After every few rides, especially in dusty conditions. Clean with appropriate cleaner and re-oil with filter oil.
Spark Plug Inspection:
Every 10-15 hours, check gap and condition. Recommended plugs often NGK BR/R series (e.g., BR9EG).
Coolant:
Mixture of distilled water and high-quality motorcycle coolant (e.g., Engine Ice, Maxima Cool-Aide) for optimal heat management.
Brake Fluid:
DOT 4 or DOT 5.1 recommended for hydraulic brake systems.
Premix Oil:
High-quality, castor-based or synthetic 2-stroke racing oil (e.g., Motul 800 2T Offroad, Maxima K2).
Engine Wear:
Piston and ring wear is common with hard use; regular top-end rebuilds (piston, rings, power valve components) are typical maintenance items every 50-100 hours.
Carburetor Jetting:
Carburetor jetting can be sensitive to altitude, temperature, and exhaust modifications; proper tuning is crucial for optimal performance and longevity.
Suspension Seals:
Front fork and rear shock seals can wear over time, leading to leaks; regular fork seal maintenance and oil changes are recommended.
Kawasaki Legacy:
Kawasaki has a long and successful history in motocross racing with the KX line, dating back decades.
Kx250 Evolution:
The KX250 2-stroke saw continuous development, with significant updates in chassis, suspension, and engine performance during the 2000s to remain competitive.
Production Period:
2005-2008 represents a specific iteration of the KX250 2-stroke before the model line transitioned primarily to 4-stroke. The 2-stroke model continued to be offered by some markets and enthusiasts for its unique characteristics.
