Kawasaki KX250 2005-2008 Service Repair Manual

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Mots clés: 2005 2006 2007 2008 Kawasaki KX Series KX250 Motorcycle Motorcycles

Variantes de produits

Description

The Kawasaki KX250 is a high-performance motocross motorcycle designed for competitive racing and enthusiast use. Covering model years 2005 through 2008, this machine is powered by a potent liquid-cooled, 2-stroke, single-cylinder engine with a displacement of 249 cc. Known for its aggressive power delivery, lightweight construction, and advanced chassis, the KX250 offers exceptional handling and responsiveness on the track, embodying a rich racing heritage. Its robust engineering ensures reliability for demanding motocross environments, making it a formidable competitor against other leading models of its era. This comprehensive Service Repair Manual provides detailed information for the maintenance and repair of the Kawasaki KX250. It covers a wide range of systems, including the engine's top and bottom ends, fuel and cooling systems, transmission, electrical components, brakes, suspension, steering, and frame. The manual offers step-by-step procedures for diagnostics, repairs, scheduled maintenance, and tune-ups, catering to both dealership technicians and DIY mechanics. With factory-level detail, including torque specifications and diagrams, this manual is an essential resource for ensuring the optimal performance and longevity of your KX250.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Model Years Covered:

2005, 2006, 2007, 2008

Vehicle Type:

Motocross Motorcycle

Codes

Engine Type Code:

2-Stroke

👋 Introduction

Market Position

Segment:

Performance Motocross Motorcycle

Target Audience:

Competitive motocross riders, enthusiasts seeking to maintain and repair their KX250.

Competitive Analysis

Competitors:

Honda CR250R, Yamaha YZ250, Suzuki RM250 of the same era.

Key Features

Vehicle Focus:

High-performance, lightweight, powerful 2-stroke engine designed for racing.

Manual Value Proposition:

Empowers owners to perform dealership-level maintenance and repairs, saving costs and ensuring optimal performance.

📋 Manual Details

Coverage Areas

General Information:

Periodic Maintenance:

Fuel System:

Cooling System:

Engine Top End:

Engine Right Side:

Engine Removal Installation:

Engine Bottom End Transmission:

Wheels Tires:

Final Drive:

Brakes:

Suspension:

Steering:

Frame:

Electrical System:

Appendix:

Page Count

Estimated Page Count:

Refer to manual for exact count; typically 300-500 pages for comprehensive service manuals.

Manual Type

Type:

Service Repair Manual

Intended User:

Dealership Technicians, DIY Mechanics

Language

Language:

English

Format

File Format:

Compatibility:

Windows, macOS

Reader Requirement:

Adobe PDF Reader

Printability:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed coverage of top-end (cylinder, piston, rings, head), bottom-end (crankshaft, connecting rod, bearings), transmission, clutch, lubrication.

Fuel System:

Carburetor overhaul, jetting, fuel lines, fuel tank inspection and maintenance.

Cooling System:

Radiator, hoses, coolant specifications, flow control (if applicable).

Chassis And Suspension:

Front fork (USD) disassembly, assembly, oil levels, damping adjustments; rear shock absorber service, linkage maintenance.

Brakes:

Hydraulic brake system, caliper service, master cylinder, brake fluid types, pad replacement, rotor inspection.

Electrical System:

Ignition system, lighting (if applicable), wiring diagrams, troubleshooting electrical faults.

Wheels And Tires:

Wheel bearing service, spoke tensioning, tire pressure recommendations, wheel removal and installation.

Final Drive:

Chain and sprocket inspection, adjustment, lubrication, and replacement procedures.

Steering And Frame:

Steering head bearing service, handlebar maintenance, frame inspection for damage or alignment issues.

Procedures Included

Diagnostics:

Step-by-step diagnostic procedures for common issues, troubleshooting guides based on symptoms.

Repair:

Detailed instructions for disassembling, inspecting, repairing, and reassembling all major components.

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points.

Tune-Up:

Carburetor tuning, ignition timing checks, general engine adjustments.

Troubleshooting:

Common problems and their solutions, diagnostic flowcharts.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine rebuilds and advanced diagnostics.

Detail Level:

Factory-level detail, including torque specifications, clearances, and special tool requirements.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within the PDF, enabling quick information retrieval.

Print Quality

Quality:

High-resolution, suitable for clear printing of text and diagrams.

Binding Type

Type:

Digital Download (PDF)

Paper Type

Not applicable for digital format.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, single cylinder

Displacement:

249 cc

Bore X Stroke:

66.4 x 72.0 mm

Compression Ratio:

9.1:1 (typical for this era, confirm in manual)

Induction:

Carburetor (e.g., Keihin PWK38S)

Ignition:

Digital CDI

Performance

Horsepower:

Approx. 45-50 HP (varies by year and specific tuning, manual will provide precise figures)

Torque:

N/A (typically not a primary spec for motocross, but manual may list)

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Octane Rating:

91 octane or higher recommended (check manual)

Fuel Mix Ratio:

Pre-mix (e.g., 50:1 or 40:1 with specific 2-stroke oil, check manual for precise ratio and oil type)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-disc

Features

Gear Ratios:

Specific ratios are detailed in the manual.

Transmission Oil Type:

API GL-4, SAE 10W-30 or 20W-40 motorcycle gear oil (check manual for exact specification and capacity).

📐 Dimensions

Exterior

Length:

Approx. 2175 mm (85.6 in) (varies slightly by year)

Width:

Approx. 820 mm (32.3 in)

Height:

Approx. 1270 mm (50.0 in)

Wheelbase:

Approx. 1475 mm (58.1 in)

Ground Clearance:

Approx. 335 mm (13.2 in)

Seat Height:

Approx. 965 mm (38.0 in)

Weights

Dry Weight:

Approx. 95 kg (209.4 lbs)

Wet Weight:

N/A (typically not published for motocross, consult manual)

🛡️ Safety Features

Ratings

Motorcycle safety ratings are not applicable in the same way as automobiles. Focus is on rider protection and vehicle stability.

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear.

Suspension:

High-performance adjustable suspension for optimal control and stability.

Passive Features

Frame Construction:

Strong and lightweight perimeter frame design.

Handlebar:

Durable handlebars with grips designed for control.

💡 Technology Features

Infotainment

Not applicable to this motocross model.

Driver Assistance

Not applicable to this motocross model.

Connectivity

Not applicable to this motocross model.

🔧 Maintenance

Service Intervals

Oil Change Transmission:

Every 15-20 hours of riding or annually (refer to manual for precise intervals and conditions).

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions (detailed cleaning and oiling procedure in manual).

Spark Plug Replacement:

Typically every 20-30 hours of riding, or based on inspection of plug condition (manual will specify).

Chain Lubrication:

After every ride or every 2-3 rides, depending on conditions.

Top End Rebuild:

Recommended every 40-60 hours of competitive use, or based on performance degradation (manual will detail wear limits).

Fluid Specifications

Engine Oil:

High-quality 2-stroke synthetic or semi-synthetic racing oil, mixed with fuel at specified ratio (e.g., 40:1 or 50:1). Manual will specify brand recommendations or standards.

Cooling System Coolant:

Mixture of distilled water and permanent antifreeze (ethylene glycol base) with corrosion inhibitors. Specific ratio and type in manual.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid (verify exact specification in manual).

Known Issues

Carburetor Tuning:

Can be sensitive to altitude and temperature changes, requiring periodic jetting adjustments.

Clutch Wear:

Clutch plates and springs can wear out with aggressive use; manual provides inspection and replacement procedures.

Suspension Seals:

Fork and shock seals can leak over time, requiring seal replacement and oil service.

Power Valve Operation:

The exhaust power valve mechanism can accumulate carbon and require cleaning for optimal performance. Manual details disassembly and cleaning.

📚 Vehicle History

Brand Heritage

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Racing Legacy:

Kawasaki has a strong heritage in motocross and supercross racing, with the KX line being a significant part of that history.

Model Evolution

Kx Line Development:

The KX250 has evolved significantly over the years, with the 2005-2008 models representing a mature generation of the liquid-cooled 2-stroke design before the transition to 4-stroke models dominance.

Production

Manufacturing Location:

Primarily Japan (verify specific assembly location from VIN or manual).

🏆 Awards & Recognition

Recognitions

While specific awards for this particular model year may not be widely publicized, the Kawasaki KX line has consistently been recognized for its performance and race-winning capabilities.