2004 Kawasaki KX250F Service Repair Manual

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Mots clés: 2004 Kawasaki KX250F Misc Motorcycle Motorcycles

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Description

The 2004 Kawasaki KX250F is a competition motocross motorcycle engineered for performance and agility. Featuring a high-revving, liquid-cooled, four-stroke engine with a displacement of 249 cc, it offers a powerful platform for off-road enthusiasts and racers. Its design prioritizes rider control and handling, incorporating advanced front and rear suspension systems and a lightweight, rigid chassis. Kawasaki's extensive history in off-road racing underscores the KX line's reputation for innovation and competitive prowess, positioning the KX250F as a formidable contender in its class. This comprehensive Service Repair Manual provides detailed information for the maintenance and repair of the 2004 Kawasaki KX250F motorcycle. It covers a wide range of systems, including the engine, fuel system, transmission, chassis, brakes, and electrical components, offering step-by-step instructions for disassembly, assembly, and troubleshooting. Routine maintenance procedures, rebuild guidance, and adjustment specifications are also included, making this manual an essential resource for owners and technicians alike to ensure the optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250F

Year:

Codes

Model Code:

KX250-N1

👋 Introduction

Market Position

Category:

Competition Motocross Motorcycle

Target Audience:

Motocross racers, off-road enthusiasts, and DIY motorcycle mechanics.

Competitive Analysis

Competitors:

Yamaha YZ250F, Honda CRF250R, Suzuki RM-Z250

Key Features

Engine Design:

High-revving, liquid-cooled, four-stroke single-cylinder engine.

Suspension:

Advanced front and rear suspension systems tuned for motocross performance.

Chassis Design:

Lightweight and rigid chassis for agility and handling.

📋 Manual Details

Coverage Areas

Manual Coverage:

Comprehensive service and repair information for the 2004 Kawasaki KX250F motorcycle.

Page Count

Page Count:

Estimated 300-400 pages (typical for detailed service manuals of this era).

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, inspection, and repair of the 250cc four-stroke engine, including cylinder head, piston, crankshaft, valve train, and lubrication system.

Fuel System:

Carburetor (Keihin MX Series) service, adjustment, troubleshooting, and component identification.

Cooling System:

Radiator, hoses, coolant specifications, and fan operation (if applicable).

Ignition System:

CDI unit, ignition coil, spark plug specifications, and troubleshooting ignition faults.

Transmission:

Gearbox disassembly, inspection, assembly, clutch operation, and transmission fluid specifications.

Drivetrain:

Chain and sprocket maintenance, inspection, and replacement procedures.

Chassis:

Frame inspection, fork (upside-down telescopic) disassembly, service, and tuning; rear shock absorber service and adjustment.

Brakes:

Front and rear hydraulic disc brake system service, including caliper disassembly, pad replacement, fluid bleeding, and master cylinder maintenance.

Wheels Tires:

Wheel bearing service, spoke tension adjustment, tire pressure recommendations, and common tire sizes.

Electrical System:

Wiring diagrams, battery maintenance, lighting system (if applicable), fuse identification, and basic troubleshooting.

Bodywork:

Plastic panel removal and installation, seat maintenance, and graphics application guidance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, and general lubrication points.

Troubleshooting:

Systematic diagnostic procedures for common starting problems, engine performance issues, braking concerns, and electrical faults.

Disassembly Assembly:

Step-by-step instructions for the complete dismantling and reassembly of major motorcycle components.

Rebuilds:

Detailed guidance for engine top-end rebuilds, clutch replacement, and suspension overhauls.

Adjustments:

Carburetor jetting and adjustment, clutch lever play, brake lever travel, and suspension sag adjustments.

Technical Depth

Depth Level:

Comprehensive, suitable for both home mechanics and professional technicians. Covers routine maintenance to complete engine and chassis overhauls.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick access to information.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, four-valve single cylinder

Displacement:

249 cc (15.2 cu. in.)

Bore X Stroke:

72.0 x 61.1 mm (2.83 x 2.41 in)

Compression Ratio:

12.5:1

Performance

Horsepower Estimated:

Approximately 38-40 HP (at crankshaft, peak)

Torque Estimated:

Approximately 20-22 lb-ft (at crankshaft, peak)

Fuel System

Carburetor:

Keihin MX36 (flat slide) with dual injectors

Fuel Type:

Unleaded gasoline, minimum octane rating 91

Lubrication

Oil Type:

SAE 10W-40 API SG or higher (check manual for specific recommendations)

🔧 Transmission

Standard

Transmission Type:

Constant mesh 5-speed

Clutch Type:

Wet multi-disc

Features

Gear Ratios:

1st: 2.357 (33/14), 2nd: 1.800 (27/15), 3rd: 1.409 (31/22), 4th: 1.166 (28/24), 5th: 0.958 (23/24)

Final Drive:

Chain drive (520 size)

📐 Dimensions

Exterior

Overall Length:

70.5 in (1790 mm)

Overall Width:

32.3 in (820 mm)

Overall Height:

50.4 in (1280 mm)

Wheelbase:

58.1 in (1475 mm)

Ground Clearance:

14.0 in (355 mm)

Seat Height:

38.4 in (975 mm)

Weights

Dry Weight:

216.1 lb (98 kg)

Curb Weight:

Not officially specified, typically around 230-240 lb with all fluids.

Fuel Tank Capacity:

2.1 gal (8.0 L)

🛡️ Safety Features

Ratings

Safety Standards:

Designed for closed-course competition use; not street legal.

Active Features

Braking System:

Dual hydraulic disc brakes (front and rear) with braided steel lines for improved feel and performance.

Passive Features

Frame Construction:

High-tensile strength steel perimeter frame providing a balance of rigidity and rider feedback.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Competition motocross bike with minimal electronic features beyond ignition and engine management).

Driver Assistance

Rider Aids:

N/A (Designed for rider input and control, no electronic rider aids).

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 8-10 hours of riding or annually. Refer to manual for specific recommendations based on riding conditions.

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions. Check manual for detail.

Chain Lubrication Adjustment:

Before every ride or as needed. Check manual for correct slack.

Spark Plug Inspection:

Every 10-15 hours of riding.

Fluid Specifications

Engine Oil Capacity:

1.0 L (1.1 US qt) without filter change; 1.1 L (1.2 US qt) with filter change.

Coolant Type:

High-quality coolant/antifreeze mixed with distilled water (50/50 ratio). Refer to manual for specific Kawasaki coolant part number.

Brake Fluid Type:

DOT 4

Transmission Oil Type:

SAE 10W-40 API SG or higher (same as engine oil, or refer to manual for specific transmission oil if different).

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve stem seals, wheel bearings, and chain/sprockets are common wear items in high-performance motocross bikes.

Carburetor Tuning:

Carburetor tuning can be sensitive to altitude, temperature, and humidity changes, requiring periodic adjustment for optimal performance.

📚 Vehicle History

Brand Heritage

Kawasaki Offroad:

Kawasaki has a long and successful history in off-road racing, particularly with its KX line, known for performance and innovation.

Model Evolution

Kx250F Introduction:

The KX250F, as a four-stroke model, emerged as Kawasaki's response to the growing popularity of the 250cc four-stroke class, competing directly with established models from other Japanese manufacturers.

2004 Model Updates:

The 2004 model likely featured refinements over its predecessor, focusing on engine performance, suspension tuning, and chassis improvements based on race feedback.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motocross Performance:

Kawasaki KX models have historically been well-regarded in motocross and Supercross for their competitive engines and chassis, often winning races and championships in various classes.