2003-2004 KAWASAKI KX250 2-STROKE KX250M Service Repair Manual Motorcycle

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Mots clés: 2003 2004 Kawasaki KX250 Misc Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the motorcycles manufactured for the 2003 and 2004 model years. These 2-stroke machines are renowned for their potent performance and agile handling, making them a formidable choice for motocross and off-road enthusiasts. Built upon an extensive motorsports heritage, the KX250 of this era represents a significant evolution, featuring advanced technologies like the Integrated Power valve System (KIPS) designed to optimize power delivery across the rev range. The engineering quality and reliability inherent in the KX line ensure a responsive and exhilarating riding experience for those who demand peak performance from their equipment. This comprehensive service manual provides detailed instructions for the maintenance, repair, and troubleshooting of your 2003-2004 KX250. Within its extensive pages, you will find in-depth coverage of all major systems, including complete engine mechanical procedures, carburetor tuning, ignition and cooling system servicing, transmission overhauls, and detailed guidance on front and rear suspension and brake system maintenance. Furthermore, the manual includes essential information on the electrical system, frame and bodywork, wheels and tires, along with routine maintenance schedules and advanced diagnostic procedures. This resource is invaluable for owners and professional technicians alike, ensuring the longevity and optimal performance of the KX250.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Model Code:

KX250M

Years Covered:

2003, 2004

Engine Type:

2-Stroke

👋 Introduction

Market Position

Target Audience:

Owners and mechanics of 2003-2004 Kawasaki KX250 2-stroke motorcycles

Purpose:

To provide comprehensive repair, maintenance, and troubleshooting guidance.

Competitive Analysis

Value Proposition:

Offers the most complete and detailed information available for this specific model and year range, essential for maintaining peak performance.

Key Features

Completeness:

The 'BEST PDF Service Manual' designation suggests a high level of detail and completeness compared to basic owner's manuals or generic repair guides.

Specificity:

Tailored specifically to the 2003-2004 KX250M model, ensuring accuracy and relevance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Page Count

Estimated Page Count:

Extensive (typically 300-600+ pages for a comprehensive motorcycle service manual)

Manual Type

Manual Type:

Service Manual / Repair Manual / Workshop Guide

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, inspection, assembly, tuning, torque specifications, piston, rings, cylinder, crankshaft, connecting rod, bearings, seals, gaskets, timing (power valve operation).

Fuel System:

Carburetor tuning (Keihin PWK), jetting, float height, power jet system, fuel lines, fuel filter, fuel tank maintenance.

Ignition System:

CDI ignition, stator, ignition coil, spark plug specifications, timing adjustments.

Cooling System:

Liquid cooling system, radiator, water pump, thermostat, coolant specifications, bleeding procedures.

Transmission:

Gearbox inspection, disassembly, assembly, gear selection, clutch operation, clutch plates, springs, hydraulic clutch system (if applicable), lubrication.

Suspension Front:

Front fork service (Show & Showa or KYB), oil type, oil level, seal replacement, bushing inspection, spring rates, adjustments (compression, rebound).

Suspension Rear:

Rear shock absorber service, linkage system maintenance, bearing inspection, seals, oil, adjustments (preload, compression, rebound).

Brakes Front:

Hydraulic front brake system, caliper service, piston replacement, seal kits, master cylinder service, brake fluid type (DOT 4), bleeding procedures, rotor inspection.

Brakes Rear:

Hydraulic rear brake system, caliper service, piston replacement, seal kits, master cylinder service, brake fluid type (DOT 4), bleeding procedures, rotor inspection.

Electrical System:

Wiring diagrams, lighting system, tail light, brake light, headlight, battery maintenance, fuses, connectors, troubleshooting electrical faults.

Frame And Bodywork:

Frame inspection, swingarm maintenance, footpegs, handlebars, seat, plastic body panels, decals, disassembly and reassembly procedures.

Wheels And Tires:

Spoke tensioning, rim inspection, wheel bearing service, tire pressure specifications, tire sizes, tube replacement.

Procedures Included

Routine Maintenance:

Oil changes (transmission oil), chain cleaning and lubrication, air filter cleaning, spark plug checks, brake adjustments, general inspection.

Troubleshooting:

Diagnostic charts for common problems (e.g., hard starting, poor performance, electrical issues), fault finding guides.

Engine Rebuild:

Step-by-step instructions for full engine overhaul, including piston replacement, crankshaft rebuild, power valve service.

Suspension Service:

Detailed procedures for servicing front forks and rear shock absorbers, including oil changes and seal replacements.

Brake System Overhaul:

Instructions for caliper rebuilding, master cylinder servicing, and bleeding the hydraulic brake system.

Carburetor Adjustment:

Comprehensive guide to tuning the Keihin PWK carburetor for optimal performance in various conditions.

Electrical Troubleshooting:

Utilizing wiring diagrams to diagnose and repair electrical system faults.

Technical Depth

Depth Level:

Comprehensive (suitable for professional mechanics and advanced DIY enthusiasts)

Diagnostic Capability:

Advanced diagnostics and troubleshooting procedures

Rebuild Instructions:

Detailed rebuild instructions for major mechanical components

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if professionally produced

Print Quality

Print Quality Recommendation:

High-resolution PDF for clear diagrams and text

Binding Type

Binding Type:

Not applicable (digital format)

Paper Type

Paper Type Recommendation:

Not applicable (digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke

Displacement:

249 cc (approx.)

Bore X Stroke:

Refer to manual for exact specifications (typically around 66.4 x 72.0 mm)

Cooling System:

Liquid-cooled

Power Valve System:

Kawasaki Integrated Power Valve System (KIPS)

Performance

Horsepower:

Refer to manual for precise figures (historically in the 40-45 HP range for this era)

Torque:

Refer to manual for precise figures

Fuel System

Carburetor Model:

Keihin PWK38

Fuel Type:

Unleaded gasoline (typically 91 octane or higher recommended)

Oil Mixture:

Pre-mix (50:1 or 40:1 with quality 2-stroke oil, refer to manual for specific recommendation)

🔧 Transmission

Standard

Type:

Constant mesh, 6-speed sequential

Optional

Optional Gear Ratios:

Refer to manual for specific ratios

Features

Clutch Type:

Wet, multiple-disc, cable-actuated or hydraulic

Transmission Oil:

Specialized motorcycle transmission oil (e.g., SAE 10W-40 or 10W-50, check manual for specific grade and capacity, typically around 0.7-1.0 L)

📐 Dimensions

Exterior

Length:

Refer to manual (typically around 2170 mm)

Width:

Refer to manual (typically around 800 mm)

Height:

Refer to manual (typically around 1270 mm)

Wheelbase:

Refer to manual (typically around 1475 mm)

Weights

Dry Weight:

Refer to manual (typically around 97 kg)

Wet Weight:

Refer to manual (includes fluids)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (motorcycle, no standardized crash ratings)

Active Features

Braking System:

Hydraulic disc brakes, front and rear

Suspension Adjustability:

Adjustable front forks and rear shock for rider preference and terrain

Passive Features

Ergonomics:

Designed for motocross riding position, ensuring rider control

Handguards:

Often equipped or easily added for hand protection

💡 Technology Features

Infotainment

Infotainment System:

N/A (motocross motorcycle)

Driver Assistance

Driver Assistance Features:

N/A (motocross motorcycle)

Connectivity

Connectivity Features:

N/A (motocross motorcycle)

Engine Technology

Kips System:

Kawasaki's KIPS (Kawasaki Integrated Power valve System) optimizes exhaust port timing for improved low-to-mid-range power delivery and top-end performance.

🔧 Maintenance

Service Intervals

Oil Change Transmission:

Every 10-15 hours of riding, or as per manual recommendation.

Air Filter Cleaning:

After every few rides or as needed depending on conditions.

Spark Plug Inspection:

Every 10-20 hours of riding.

Chain Lubrication:

Before every ride or as needed.

Top End Rebuild:

Intervals vary greatly with usage (e.g., 40-80 hours for piston, more for cylinder and crank).

Fluid Specifications

Transmission Oil Grade:

SAE 10W-40 or 10W-50 (verify with manual)

Brake Fluid Type:

DOT 4 (verify with manual)

Coolant Type:

High-quality ethylene glycol-based coolant (50/50 mix with distilled water, verify with manual)

Fork Oil Type:

Specific fork oil viscosity (e.g., 5W, 10W, refer to manual for exact specification and level)

Known Issues

Power Valve Sticking:

Can occur due to carbon buildup, requiring regular cleaning.

Clutch Wear:

Clutch plates and springs can wear over time with aggressive riding.

Suspension Seals:

Fork and shock seals can degrade, leading to oil leaks.

Carburetor Jetting:

Proper jetting is crucial for optimal performance and engine longevity, often requiring adjustment for altitude and temperature.

📚 Vehicle History

Brand Heritage

Kawasaki Motorsports:

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

Model Evolution

Kx Series:

The KX250 model has undergone continuous development, evolving from its early air-cooled iterations to the liquid-cooled, high-performance machines of the early 2000s.

2003-2004 Kx250:

These model years represented a period of refinement for the KX250, incorporating advancements in suspension, chassis, and engine tuning to remain competitive in the highly contested 250cc motocross class.

Production

Manufacturing Location:

Japan (typically)

🏆 Awards & Recognition

Recognitions

Motocross Contributions:

The KX250 platform has a history of success in professional motocross and supercross racing, indicative of its performance capabilities.

Ratings

Industry Perception:

Highly regarded as a competitive and capable 250cc two-stroke motocross bike for its era.