🏷️ Basic Information

Make:

Kawasaki

Model:

KX250

Year:

2008

Product Type:

Factory Service Repair Manual

👋 Introduction

Positioning:

High-performance motocross competition machine, successor to a long line of successful KX models.

Competitors:

Primary competitors include Yamaha YZ250, Honda CR250R, and KTM 250 SX.

Engine Type:

Liquid-cooled, two-stroke, single-cylinder engine.

Suspension Front:

Kayaba (Showa) 48mm Upside-down telescopic fork with adjustable compression and rebound damping.

Suspension Rear:

Uni-Trak linkage system with Kayaba (Showa) shock absorber, adjustable preload, compression, and rebound damping.

Brakes Front:

Hydraulic disc brake with 250mm rotor.

Brakes Rear:

Hydraulic disc brake with 240mm rotor.

Transmission:

5-speed constant mesh, return shift.

📋 Manual Details

Engine Service:

Complete engine disassembly, assembly, inspection, repair, and troubleshooting.

Transmission Service:

Clutch, gearbox, and final drive maintenance and repair.

Chassis Suspension:

Front forks (cartridge/spring), rear shock absorber, linkage, swingarm, and steering system.

Brakes:

Front and rear brake system inspection, service, and bleeding procedures.

Electrical System:

Ignition system, lighting, charging system, and wiring diagrams.

Fuel System:

Carburetor disassembly, adjustment, cleaning, and fuel tank/line maintenance.

Cooling System:

Radiator, hoses, and coolant specifications and service.

Exhaust System:

Exhaust pipe and silencer inspection and service.

Bodywork Frame:

Frame inspection, seat, fuel tank, body panels, and graphics removal/installation.

Troubleshooting:

Diagnostic procedures for common problems and fault finding.

Estimated Pages:

Approx. 300-400 pages (typical for this model's factory manual).

Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Cylinder head, piston, connecting rod, crankshaft, valve train, lubrication system.

Engine Electrical:

CDI ignition, spark plug, stator, flywheel, wiring harness.

Transmission Drivetrain:

Gear shifting mechanism, clutch plates, basket, gears, bearings.

Suspension Steering:

Front fork oil levels, pressures, seal replacement; rear shock adjustments, linkage bearing service.

Braking System:

Hydraulic lines, caliper piston service, master cylinder overhaul, brake pad replacement.

Wheels Tires:

Spoke tensioning, rim inspection, tire mounting, wheel bearing service.

Fuel Carburetion:

Keihin PWK carburetor tuning, jetting, float bowl maintenance, choke operation.

Cooling Radiator:

Radiator flush, coolant type (e.g., 50/50 ethylene glycol mix), water pump seal replacement.

Frame Body:

Frame integrity checks, handlebar replacement, footpeg mounting.

Disassembly Assembly:

Detailed step-by-step instructions for component removal and reinstallation.

Inspection Measurement:

Torque specifications for all fasteners, wear limits for engine components (piston, cylinder bore), bearing clearances.

Troubleshooting Diagnostics:

Flowcharts and guides for identifying and resolving common performance issues.

Maintenance Adjustments:

Carburetor jetting adjustments, chain tensioning, valve clearance checks (if applicable to this 2-stroke model), spark plug gap.

Special Tools:

Listing and description of specialized tools required for specific procedures (e.g., flywheel puller, clutch holder tool).

Wiring Diagrams:

Comprehensive electrical schematics for easy diagnosis of electrical faults.

Depth:

Comprehensive rebuild and diagnostic capabilities, suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes, text-searchable for quick information retrieval.

Resolution:

High-resolution scans for clear text and diagrams.

Printable:

Yes, allows for printing of individual sections or the entire document.

Quality:

N/A (Digital Format)

Type:

N/A (Digital Format)

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, two-stroke, single-cylinder

Displacement:

249 cc

Bore X Stroke:

66.4 x 72.0 mm

Compression Ratio:

8.8:1 (typical for this era KX250)

Valve System:

Reed valve intake, KIPS (Kawasaki Integrated Powervalve System) exhaust port.

Horsepower Est:

Approx. 45-50 HP at the crank (estimated, factory data not always published for competition models).

Torque Est:

Approx. 30-34 lb-ft at the crank (estimated).

Carburetor:

Keihin PWK38 (38mm flat slide carburetor) with throttle position sensor (TPS).

Fuel Type:

Unleaded gasoline, 91 octane (minimum recommended for optimal performance).

Premix Ratio:

50:1 ratio of high-quality 2-stroke oil to gasoline.

🔧 Transmission

Type:

5-speed constant mesh, return shift

Clutch:

Wet multi-disc, manual operation.

Final Drive:

#520 O-ring sealed chain.

Kips System:

Kawasaki Integrated Powervalve System (KIPS) for improved low-to-mid range power delivery and top-end acceleration.

📐 Dimensions

Length Overall:

Approx. 2170 mm (85.4 in)

Width Overall:

Approx. 800 mm (31.5 in)

Height Overall:

Approx. 1255 mm (49.4 in)

Wheelbase:

Approx. 1475 mm (58.1 in)

Ground Clearance:

Approx. 355 mm (14.0 in)

Seat Height:

Approx. 965 mm (38.0 in)

Dry Weight:

Approx. 95 kg (209.4 lbs)

Curb Weight:

Not typically specified by Kawasaki for this model.

Fuel Capacity:

8.0 liters (2.1 US gal)

🛡️ Safety Features

Safety Features:

Designed for closed-course competition; no safety ratings typically apply to street use.

Braking Performance:

Powerful hydraulic disc brakes front and rear for strong stopping power.

Suspension Stability:

Adjustable suspension provides optimal handling and stability over varied terrain.

Frame Construction:

High-strength perimeter frame for rigidity and rider feedback.

💡 Technology Features

Features:

N/A (Competition motocross bike, no infotainment systems).

Features:

N/A (Focus is on rider control and mechanical feedback).

Features:

N/A (No electronic connectivity features).

System:

KIPS (Kawasaki Integrated Powervalve System) for optimizing power delivery across the rev range via electronic control of the exhaust port timing.

🔧 Maintenance

Oil Change:

Transmission oil (Kawasaki Genuine Gear Oil SAE 10W-30 or equivalent) should be changed every 10-15 hours of operation.

Air Filter:

Clean or replace the air filter every 5-10 hours of operation, more frequently in dusty conditions.

Spark Plug:

Inspect spark plug (NGK BR9EG or equivalent) every 10-15 hours, replace as needed. Check gap (0.6-0.7 mm).

Chain Tension:

Adjust drive chain free play (20-30mm) every 5-10 hours.

Engine Top End:

Top-end rebuild (piston and rings) recommended every 25-40 hours of hard use.

Engine Oil Type:

High-quality 2-stroke motorcycle oil, pre-mix ratio 50:1.

Transmission Oil Type:

Kawasaki Genuine Gear Oil SAE 10W-30 (or equivalent API GL-4 specification).

Coolant Type:

50/50 mixture of ethylene glycol-based coolant and distilled water.

Fork Oil:

Front fork oil: Showa SS-07 or equivalent (SAE 5W). Capacity: 330-345 ml per leg (refer to manual for exact adjustment).

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Clutch Wear:

Clutch plates can wear prematurely with aggressive riding; regular inspection and adjustment are necessary.

Carburetor Fouling:

Carburetor jetting may require fine-tuning based on altitude, temperature, and riding style to prevent fouling or lean conditions.

Kips System Sticking:

KIPS system can accumulate carbon deposits and may require periodic cleaning to ensure proper operation.

Suspension Seals:

Fork and shock seals can leak over time due to harsh riding conditions; require regular inspection and potential replacement.

📚 Vehicle History

Heritage:

Kawasaki has a long and storied history in motocross, with the KX line being a dominant force for decades.

Evolution 2008:

The 2008 model represented a refinement of the successful KX250 platform, focusing on improved suspension, chassis geometry, and engine tuning for enhanced competition performance.

Predecessors:

Builds upon the legacy of the KX250, which transitioned from air-cooled to liquid-cooled engines and saw continuous chassis and engine development.

Manufacturing Location:

Japan

Production Years:

The KX250 two-stroke was produced through the 2007 model year in many markets, with some regions potentially offering the 2008 model as a carry-over or updated version. Kawasaki later introduced a KX250F (four-stroke).

🏆 Awards & Recognition

Motocross Wins:

Kawasaki KX models have historically been strong performers and frequent winners in professional motocross and supercross championships.

Magazine Reviews:

Often praised for its strong engine performance and capable suspension by industry publications of its time.