Kawasaki KX250 2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KX250 Year: 2006 Vehicle Type: Motocross Motorcycle Generation Generation Designation: Second Generation KX250 (2005-2007) 👋 Introduction Market Position Target Audience: DIY motocross enthusiasts,...

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Mots clés: 2006 Kawasaki KX Series KX250 Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Year:

Vehicle Type:

Motocross Motorcycle

Generation

Generation Designation:

Second Generation KX250 (2005-2007)

👋 Introduction

Market Position

Target Audience:

DIY motocross enthusiasts, independent repair shops, and Kawasaki service technicians.

Purpose:

To provide authoritative, manufacturer-level repair and maintenance information for the KX250 model.

Competitive Analysis

Comparison Point:

Offers more detail and accuracy than generic aftermarket repair guides.

Key Features

Accuracy:

Based on original factory specifications and procedures.

Comprehensiveness:

Covers all aspects of the motorcycle's mechanical and electrical systems.

Usability:

Organized for ease of reference with clear language and illustrations.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

Page Count

Page Count Estimated:

400-500 pages (typical for this era of factory service manuals)

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, troubleshooting, and repair of the 2-stroke engine.

Fuel System:

Carburetor tuning, cleaning, and overhaul; fuel tank and line maintenance.

Ignition System:

CDI system, spark plug specifications, troubleshooting ignition faults.

Cooling System:

Radiator, hoses, and coolant specifications for liquid-cooled engine.

Transmission:

Gearbox disassembly, assembly, inspection, and lubrication.

Clutch:

Clutch plate replacement, clutch lever adjustment, hydraulic clutch system (if applicable).

Suspension:

Front fork (USD) disassembly, assembly, oil levels, and pressure adjustments; rear shock absorber rebuild and settings.

Brakes:

Front and rear brake caliper overhaul, master cylinder service, brake pad replacement, fluid specifications (DOT 4).

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, spoke tensioning.

Electrical System:

Wiring diagrams, lighting system, battery maintenance, troubleshooting electrical faults.

Frame Chassis:

Frame inspection, steering head bearing service, swingarm bearing maintenance.

Bodywork:

Fairing removal and installation, seat, fenders, and fuel tank component service.

Procedures Included

Basic Maintenance:

Regular checks, lubrication points, filter cleaning/replacement, chain adjustment.

Intermediate Repair:

Component replacement (e.g., brake pads, clutch plates, wheel bearings), fluid changes.

Advanced Rebuild:

Full engine disassembly and reassembly, carburetor rebuilding, suspension fork and shock rebuild.

Troubleshooting:

Diagnostic procedures for common starting, running, and performance issues.

Adjustment:

Carburetor jetting, ignition timing, clutch and throttle cable free play, suspension sag.

Specifications:

Torque specifications for all fasteners, measurement tolerances, wear limits.

Technical Depth

Depth Level:

Comprehensive, from basic checks to complete engine rebuilds and chassis overhauls.

Diagrams Illustrations:

Detailed exploded diagrams and step-by-step illustrations for component assembly and disassembly.

Diagnostic Charts:

Troubleshooting charts organized by symptom for efficient problem diagnosis.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes (typically, for digital formats)

Printable:

Print Quality

Image Resolution:

High resolution for clear diagrams and text (typical for factory manuals).

Binding Type

Binding Type Physical:

N/A (Digital)

Paper Type

Paper Type Physical:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

249 cc (15.19 cu in)

Bore X Stroke:

66.4 x 72.0 mm (2.61 x 2.83 in)

Compression Ratio:

9.7:1

Performance

Horsepower Est:

Approx. 44-46 HP (at crank, manufacturer figures vary slightly by region)

Torque Est:

Approx. 27-29 lb-ft (at crank)

Fuel System

Carburetor:

Keihin PWK39, Single

Fuel Type:

Unleaded gasoline, 91 octane or higher recommended.

Fuel Mixture:

2-stroke engine oil mixed with gasoline at 30:1 or 50:1 ratio (refer to manual for precise specification).

Ignition System

Ignition:

Digital CDI

Lubrication

Lubrication Type:

Premix or Oil Injection (confirm model variation, though 2006 KX250 typically used premix).

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, sequential manual

Gear Ratios:

Specific ratios detailed in manual (e.g., 1st: 2.462, 2nd: 1.765, 3rd: 1.400, 4th: 1.150, 5th: 0.960 - typical for this model).

Optional

Optional Gearing:

Aftermarket sprockets and chain kits available, but not factory options.

Features

Clutch Type:

Wet, multi-disc

Final Drive:

Chain

Transmission Oil Spec:

Kawasaki especific transmission oil or equivalent SAE 10W-30 API SE, SF, or SG.

📐 Dimensions

Exterior

Length:

Approx. 85.0 in (2160 mm)

Width:

Approx. 32.3 in (820 mm)

Height:

Approx. 50.0 in (1270 mm)

Wheelbase:

Approx. 57.9 in (1470 mm)

Ground Clearance:

Approx. 13.2 in (335 mm)

Seat Height:

Approx. 38.4 in (975 mm)

Weights

Dry Weight:

Approx. 211.7 lb (96 kg)

Curb Weight Est:

Approx. 230-235 lb (104-107 kg) with all fluids.

Fuel Capacity:

2.4 gal (9.0 L)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety ratings are not typically provided in the same manner as automobiles).

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Suspension Stability:

Long-travel suspension aids in maintaining control over rough terrain.

Passive Features

Chassis Design:

Perimeter frame designed for rigidity and rider control.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Basic motocross bike with no digital infotainment systems).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids or driver assistance systems).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Transmission:

Every 6-10 hours of riding or annually, whichever comes first (refer to manual for precise interval).

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions.

Chain Lubrication Adjustment:

Every ride or every 500 miles (800 km).

Spark Plug Replacement:

Inspect every 5-10 hours, replace as needed.

Top End Rebuild:

Highly dependent on riding style and conditions, typically every 20-40 hours for competitive use.

Fluid Specifications

Engine Oil Type:

2-stroke premix oil (e.g., Motul 800, Yamalube 2R) mixed with gasoline.

Coolant Type:

Kawasaki Coolant or equivalent ethylene glycol-based coolant with distilled water (50/50 mix).

Brake Fluid Type:

DOT 4

Known Issues

Power Valve Sticking:

Common in 2-strokes if not regularly cleaned and serviced due to carbon buildup.

Carburetor Jetting:

Can be sensitive to altitude and temperature changes, requiring tuning.

Clutch Wear:

Clutch plates can wear depending on riding style and frequency of use.

Suspension Seals:

Fork and shock seals can leak over time and require replacement.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long and successful history in motocross racing with the KX line, dating back to the 1970s.

Model Evolution

Kx250 2006 Context:

The 2006 model represents a refinement of the second-generation KX250, featuring improvements based on racing feedback.

Predecessor Features:

Continued the legacy of strong, tractable power delivery characteristic of Kawasaki's 2-stroke motocross bikes.

Production

Production Period:

The KX250 2-stroke was produced for many years, with significant updates in the mid-2000s leading up to the discontinuation of the 2-stroke model.

🏆 Awards & Recognition

Recognitions

Motocross Accolades:

Kawasaki KX models consistently received positive reviews and accolades in motocross publications during their production years for performance and handling.

Ratings

Performance Ratings:

Highly regarded for its potent 2-stroke engine and competitive chassis geometry in its class.

Certifications

Factory Certification:

This manual is a Factory Service Manual, indicating it's the official documentation from Kawasaki.