Kawasaki KX250F KX 250F 2010 Service Repair Workshop Manual Download PDF

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Mots clés: 2010 Kawasaki KX 250F KX Series KX250F Motorcycle Motorcycles

Variantes de produits

Description

The 2010 model is a dedicated motocross competition motorcycle engineered for peak performance on the track. This model features a liquid-cooled, 249 cc four-stroke engine with DOHC and four valves, complemented by a digital fuel injection system for precise throttle response. Its design emphasizes agility and control, incorporating a lightweight aluminum perimeter frame and high-performance suspension components, including advanced front forks and a rear shock absorber. With a focus on racing, the model offers a powerful and responsive riding experience, building on a strong legacy in motocross competition. This comprehensive Service Repair Workshop Manual provides in-depth guidance for maintaining and repairing the 2010 model. It covers all essential systems, including engine mechanicals, fuel injection, cooling, ignition, transmission, chassis, suspension, and braking systems. The manual details routine maintenance procedures, engine rebuilds, suspension servicing, and troubleshooting for common issues, offering factory-level technical information with hundreds of photos and exploded diagrams. Its purpose is to empower owners, mechanics, and technicians with the knowledge required to keep this high-performance machine in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250F

Year:

Codes

Internal Model Code:

KX250X (likely, as is common for F-model motocross bikes)

👋 Introduction

Market Position

Vehicle Type:

Motocross Competition Motorcycle

Target Audience:

Motocross racers and performance-oriented off-road enthusiasts

Competitive Analysis

Key Competitors 2010:

Yamaha YZ250F, Honda CRF250R, Suzuki RM-Z250, KTM 250 SX-F

Key Features

Engine Technology:

Fuel-injected, liquid-cooled, DOHC, four-valve, four-stroke engine

Suspension Technology:

High-performance front forks and rear shock absorber for superior handling and adjustability

Chassis Design:

Lightweight and rigid aluminum perimeter frame for precise handling and stability

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Hundreds (as stated in product description, typical for factory service manuals)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, inspection, repair, and reassembly for all internal components (piston, rings, cylinder, crankshaft, connecting rod, valves, camshafts, timing chain, etc.)

Fuel System:

Fuel injection system (throttle body, injectors, ECU, sensors), fuel pump, fuel tank, fuel filter

Cooling System:

Radiators, coolant hoses, water pump, thermostat

Ignition System:

ECU, ignition coils, spark plug, wiring

Transmission:

Clutch operation, gears, shift drum, shift forks, transmission bearings, gear ratios

Chassis Frame:

Frame inspection, welds, headstock, swingarm pivot

Suspension Front:

Front fork disassembly, service, oil changes, seal replacement, spring rates, damping adjustments

Suspension Rear:

Rear shock absorber service, linkage maintenance, bearing inspection, shock linkage lubrication

Brakes Front:

Brake caliper service, brake pad replacement, master cylinder maintenance, brake line routing, rotor specifications

Brakes Rear:

Rear brake caliper service, brake pad replacement, master cylinder maintenance, brake line routing, rotor specifications

Wheels Tires:

Wheel bearing service, spoke tension, tire pressure recommendations, rim specifications

Electrical System:

Wiring diagrams, component testing (sensors, actuators), battery maintenance, lighting (if applicable to off-road models)

Bodywork Fairings:

Fairing removal and installation, seat, fuel tank cover, fender components

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug replacement, valve clearance checks

Troubleshooting:

Diagnostic flowcharts for common starting, running, and electrical issues

Engine Rebuild:

Complete engine overhaul procedures, including torque specifications for all fasteners

Suspension Service:

Detailed procedures for fork and shock absorber servicing, including oil types and quantities

Brake System Service:

Brake bleeding, pad and rotor replacement, caliper overhaul

Clutch Replacement:

Clutch plate replacement, spring inspection, clutch cover gasket replacement

Fuel Injection Diagnosis:

Troubleshooting fuel delivery and sensor issues related to the EFI system

Wiring Diagram Analysis:

Interpreting and using the provided wiring schematics for diagnostic purposes

Technical Depth

Depth Of Coverage:

Factory-level, comprehensive coverage for all repair, maintenance, and diagnostic procedures

Diagrams Illustrations:

Hundreds of detailed photos and exploded diagrams

Diagnostic Information:

Includes specific fault codes and troubleshooting trees for EFI system issues

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable, enhancing usability for finding specific information

Print Quality

Printability:

Printable (single page or entire manual)

Binding Type

Digital Binding:

N/A (downloadable digital format)

Paper Type

Digital Paper Type:

N/A (digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, four-valve single-cylinder

Displacement:

249 cc

Bore X Stroke:

77.0 x 53.6 mm

Compression Ratio:

13.2:1 (typical for this era)

Cooling System:

Liquid-cooled

Performance

Horsepower Estimate:

Approx. 38-40 hp (at crank, for comparison)

Torque Estimate:

Approx. 18-19 lb-ft (at crank, for comparison)

Fuel System

Fuel Delivery:

Digital Fuel Injection (DFI) with 43mm Keihin throttle body

Fuel Type:

Unleaded premium gasoline

Ignition

Ignition System:

Digital CDI with variable ignition timing

Lubrication

Engine Oil Capacity:

Approx. 0.70 L (1.48 US qt) without filter change; 0.80 L (1.69 US qt) with filter change (verify in manual)

Engine Oil Type:

SAE 10W-40, API SG or higher, JASO MA certified (verify in manual for specific recommendations)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, return shift

Clutch Type:

Wet multi-disc

Features

Gear Ratios:

Specific ratios detailed in manual (e.g., 1st: 2.750, 2nd: 1.944, 3rd: 1.533, 4th: 1.227, 5th: 1.045)

Final Drive:

Chain drive (typically 13T front sprocket, 49T rear sprocket, verify)

Transmission Oil Capacity:

Approx. 0.60 L (0.63 US qt) (verify in manual)

Transmission Oil Type:

SAE 10W-40, API SG or higher, JASO MA certified (verify in manual for specific recommendations)

📐 Dimensions

Exterior

Overall Length:

Approx. 2185 mm (86.0 in)

Overall Width:

Approx. 820 mm (32.3 in)

Overall 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. 955 mm (37.6 in)

Weights

Curb Weight:

Approx. 99.6 kg (220 lbs) (typically without fuel)

Dry Weight:

N/A (typically not specified for fuel-injected bikes in this category, curb weight is more relevant)

Fuel Tank Capacity:

Approx. 7.0 L (1.8 US gal)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not Applicable (competition off-road vehicle)

Active Features

Brakes:

Hydraulic disc brakes front and rear

Passive Features

Frame Construction:

High-tensile steel perimeter frame, designed for rigidity and impact resistance

💡 Technology Features

Infotainment

Infotainment System:

None (as it's a dedicated motocross bike, focus is on performance, not rider comfort features).

Driver Assistance

Traction Control:

Launch Control:

None (typically not equipped on this model)

Connectivity

Bluetooth Wifi:

Performance Tuning

Efi Tuning Options:

While the manual covers diagnosis, aftermarket EFI tuning tools and maps are available for further customization.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 15-20 hours of riding or as specified by manual (e.g., after race events).

Air Filter Cleaning:

Frequently, depending on riding conditions (e.g., every 5-10 hours or after dusty rides).

Spark Plug Replacement:

Refer to manual; typically 20-30 hours for optimal performance.

Valve Clearance Check:

Initial check at ~10 hours, then every 20-30 hours or as per manual recommendations.

Chain Lubrication Adjustment:

Regularly, depending on riding conditions.

Fluid Specifications

Engine Oil Spec:

SAE 10W-40, API SG or higher, JASO MA certified (specific brand recommendations available in manual).

Coolant Type:

Permanent type antifreeze coolant (50/50 mixture with distilled water) - verify in manual.

Brake Fluid Type:

DOT 4 hydraulic brake fluid (verify in manual).

Known Issues

Common Wear Items:

Piston, piston rings, clutch plates, wheel bearings, steering head bearings, fork seals.

Efi System Potential:

While advanced, EFI components (sensors, injectors) can require specific troubleshooting if issues arise.

Suspension Maintenance Importance:

Due to the high-performance nature, regular fork and shock service is critical for optimal performance and longevity.

📚 Vehicle History

Brand Heritage

Kawasaki Offroad Legacy:

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

Model Evolution

Kx250F Development:

The KX250F has undergone continuous development, transitioning from carbureted to fuel-injected models, with chassis and suspension advancements each year.

2010 Model Updates:

The 2010 model saw significant updates including the adoption of fuel injection, revised chassis geometry, and updated suspension components compared to previous years.

Production

Manufacturing Location:

Likely Japan or specialized off-road manufacturing facilities.

🏆 Awards & Recognition

Recognitions

Motocross Magazine Awards:

The KX250F platform has historically received numerous awards and 'bike of the year' accolades from motocross publications for its performance and handling.

Ratings

Competitor Comparisons:

Consistently ranked highly in head-to-head comparisons with its Japanese and European competitors.