Kawasaki KX250 1992-1993 Workshop Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 154357

Tags: 1992 1993 Kawasaki KX250 Misc Motorcycle Motorcycles

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Description

Introducing the Kawasaki KX250, a celebrated motocross machine produced for the 1992 and 1993 model years. Known for its strong power delivery, capable suspension, and competitive performance in the 250cc class, this motorcycle has a rich heritage in off-road racing. The KX250 line represents a significant evolution in motocross technology, offering refined chassis geometry and potent engine characteristics that made it a formidable competitor against its contemporaries. Built with a high-tensile steel perimeter frame, this model was engineered for both rigidity and impact resistance, embodying Kawasaki's commitment to performance and durability in the demanding world of motocross. This comprehensive workshop service repair manual provides in-depth guidance for the Kawasaki KX250 (chassis codes KX250-K1 for 1992 and KX250-K2 for 1993). It covers all essential aspects of maintenance, troubleshooting, diagnostics, and repair, including detailed procedures for the engine, transmission, chassis, brakes, and electrical systems. The manual is designed to assist owners, mechanics, and technicians in keeping this vintage performance machine running optimally, offering step-by-step instructions, torque specifications, and clear diagrams. With its extensive coverage, this manual is an invaluable resource for preserving the integrity and performance of your KX250.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Year:

1992, 1993

Codes

Chassis Codes:

KX250-K1 (1992), KX250-K2 (1993)

Engine Codes:

Not explicitly provided in product info, but typically consistent with chassis for this model era.

👋 Introduction

Market Position

Segment:

Motocross Competition (250cc class)

Target Audience:

Motocross racers, off-road enthusiasts, mechanics, and owners seeking to maintain and repair their KX250.

Competitive Analysis

Key Competitors:

Yamaha YZ250, Honda CR250R, Suzuki RM250.

Key Features

Vehicle Appeal:

Known for strong power delivery, capable suspension, and competitive performance in its class during the early 90s.

Manual Value Proposition:

Provides the essential technical knowledge to keep a vintage performance machine running optimally, saving on dealership service costs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Overhauls

Page Count

Estimated Page Count:

Estimated 300-500 pages (typical for a full workshop manual of this era).

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Likely Digital (PDF) based on common sales practice for older manuals.

📖 Manual Coverage

Systems Covered

Engine:

Top-end rebuild, bottom-end assembly, carburetor tuning, ignition system, cooling system (if applicable, though primarily air-cooled), exhaust system.

Transmission:

Gearbox disassembly, inspection, assembly, clutch operation and adjustment, shift mechanism.

Chassis:

Frame inspection, suspension (forks, shock absorber), steering system, wheel bearings, swingarm.

Brakes:

Front and rear brake system (hydraulic disc), caliper service, master cylinder, brake fluid replacement.

Electrical:

Wiring diagrams, lighting system, ignition coil, CDI unit, spark plug diagnosis, stator/rotor (ignition source).

Bodywork And Trim:

Seat removal, fuel tank mounting, plastics, handlebars, controls.

Procedures Included

Routine Maintenance:

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

Troubleshooting:

Diagnosis of common running issues, performance problems, starting difficulties, electrical faults.

Repair And Overhaul:

Complete engine rebuild, transmission overhaul, suspension servicing, brake caliper rebuilding.

Adjustments:

Carburetor jetting and adjustments, clutch and throttle cable free play, suspension sag.

Technical Depth

Depth:

In-depth mechanical and electrical repair, detailed component diagrams, torque specifications, special tool recommendations.

Diagnostic Procedures:

Detailed symptom-based troubleshooting guides, component testing procedures.

📊 Manual Specifications

File Format

Digital Format:

PDF (presumed), with searchable text for efficient navigation.

Print Quality

Quality:

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

Binding Type

Physical Binding:

N/A (assuming digital format).

Paper Type

Physical Paper:

N/A (assuming digital format).

⚙️ Engine Specifications

Primary Engine

Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

249 cc

Bore X Stroke:

67.4 mm x 70.0 mm

Compression Ratio:

Typically around 8.5:1 (specific value to be confirmed by manual).

Performance

Horsepower:

Estimated 45-50 HP (peak power, exact figures to be confirmed by manual).

Torque:

Estimated 30-33 lb-ft (peak torque, exact figures to be confirmed by manual).

Fuel System

Carburetor:

Mikuni VM29SS (likely, specific model to be confirmed by manual).

Fuel Type:

Unleaded gasoline (high octane recommended for 2-stroke).

Lubrication

Mixture Oil:

2-stroke engine oil pre-mix (ratio specified in manual, typically 32:1 or 40:1).

Ignition

System:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch:

Wet, multi-disc

Features

Gear Ratios:

Detailed gear ratios for each speed will be provided in the manual.

Final Drive:

Chain drive (sprocket sizes typically 13T front, 48T rear, but variations exist).

📐 Dimensions

Exterior

Length:

Approximately 2150 mm (7.05 ft)

Width:

Approximately 820 mm (2.69 ft)

Height:

Approximately 1225 mm (4.02 ft)

Wheelbase:

Approximately 1475 mm (58.1 in)

Weights

Dry Weight:

Approximately 103 kg (227 lbs)

Wet Weight:

Estimated around 108-110 kg (238-243 lbs) with fluids.

Fuel Capacity:

Approximately 9.0 liters (2.4 US gal)

🛡️ Safety Features

Ratings

Crash Test Results:

Not applicable for off-road competition vehicles of this era.

Active Features

Braking System:

Dual hydraulic disc brakes (front and rear) for strong stopping power.

Passive Features

Frame Construction:

High-tensile steel perimeter frame for rigidity and impact resistance.

💡 Technology Features

Infotainment

Features:

N/A - This is a competition motocross bike; no infotainment systems are present.

Driver Assistance

Features:

N/A - No electronic driver assistance systems.

Connectivity

Features:

N/A - No connectivity features.

🔧 Maintenance

Service Intervals

Oil Change:

Every 10-15 hours of riding (or as specified in manual).

Air Filter Cleaning:

After every riding session or as needed based on conditions.

Spark Plug Inspection:

Every 20-30 hours of riding.

Piston Ring Replacement:

Recommended every 50-75 hours of riding for optimal performance.

Top End Rebuild:

Recommended every 100-150 hours of riding (or based on compression loss).

Fluid Specifications

Engine Oil:

High-quality 2-stroke pre-mix oil (specific brand recommendations in manual).

Transmission Oil:

API GL-4, SAE 80 or 85W gear oil (capacity typically around 1 liter).

Brake Fluid:

DOT 3 or DOT 4 brake fluid (specific type specified in manual).

Coolant:

For liquid-cooled engines, typically a 50/50 mix of ethylene glycol antifreeze and distilled water (this model is primarily air-cooled, but radiators for oil cooling may exist or secondary cooling systems on some variants).

Known Issues

Common Wear Items:

Clutch plates, piston rings, chain and sprockets, wheel bearings, fork seals, shock linkage bearings.

Performance Degradation:

Loss of top-end power due to worn piston rings or cylinder, carburetor jetting issues, exhaust port carbon buildup.

Suspension Wear:

Leaking fork seals, worn shock absorber damping, or degraded bushings.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

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

Model Evolution

Kx250 Development:

The early 90s KX250 models were significant evolutionary steps, refining the chassis, engine performance, and suspension compared to previous generations.

Technological Advancements:

Key advancements during this period included improved suspension damping, more powerful engines, and refined chassis geometry.

Production

Manufacturing Location:

Primarily Japan.

🏆 Awards & Recognition

Recognitions

Motocross Performance:

The KX250 line consistently received praise and accolades in motocross magazines and competition for its performance and handling during this era.

Industry Recognition:

Likely awarded 'Best in Class' or similar titles by specialized publications for its performance metrics.