Engine:
Detailed disassembly, assembly, inspection, and repair of the 2-stroke engine, including top-end (cylinder, piston, rings, cylinder head), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable), and ignition system.
Transmission Drivetrain:
Complete coverage of the transmission system, including clutch operation, gear selection, shift forks, transmission shafts, bearings, and final drive (chain and sprockets).
Fuel System:
Carburetor service, adjustment, and overhaul. Fuel tank inspection and cleaning. Fuel line maintenance.
Ignition Electrical:
Ignition system components (CDI, ignition coil), troubleshooting electrical circuits, lighting system (if applicable), wiring diagrams, battery maintenance.
Suspension:
Front fork (upside-down) disassembly, assembly, oil change, seal replacement, and adjustment. Rear shock absorber service and adjustment. Linkage system maintenance.
Brakes:
Front and rear hydraulic disc brake systems. Master cylinder overhaul, caliper service, pad replacement, fluid bleeding, and line inspection.
Chassis Frame:
Frame inspection and repair. Handlebar and control lever adjustments. Footpeg and pedal maintenance. Seat removal and installation.
Bodywork Cosmetics:
Plastic body panel removal and installation (fenders, shrouds, number plates). Graphics and decal application.
Maintenance:
Routine maintenance checks, lubrication points, air filter cleaning, spark plug replacement, chain adjustment, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common starting, running, and performance issues. Fault finding charts.
Repair Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for virtually all mechanical and electrical systems.
Installation Adjustment:
Correct procedures for installing new parts, adjusting controls, suspensions, and engine parameters.
Depth Level:
Factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers complete engine rebuilds, transmission overhauls, and advanced suspension tuning.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
249 cc (15.2 cu in)
Bore X Stroke:
70.0 x 64.0 mm (2.76 x 2.52 in)
Compression Ratio:
8.5:1 (typical for this era, check specific spec)
Valvetrain:
Reed valve induction, KIPS (Kawasaki Integrated Power-valve System)
Horsepower:
Approx. 45-50 HP (estimated, varies with tuning)
Torque:
Approx. 28-30 lb-ft (estimated, varies with tuning)
Carburetor:
Keihin PWK38, 38mm, flat slide
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended.
Fuel Mixture:
50:1 ratio with high-quality 2-stroke oil (e.g., Yamalube 2R, Motul 800).
Safety Certification:
Not applicable (competition off-road vehicle)
Braking System:
Dual piston front caliper, single piston rear caliper, hydraulic disc brakes front and rear.
Suspension Control:
Adjustable compression and rebound damping on front forks and rear shock absorber.
Frame Construction:
High-tensile steel perimeter frame designed for strength and rigidity.
Handlebars:
Strong aluminum handlebars with protective pad.
Oil Change:
Engine oil (transmission oil): Every 10-15 hours of riding or annually. Fork oil: Every 20-30 hours or annually. Refer to manual for specific recommendations.
Air Filter:
Clean after every few rides, depending on conditions. Replace as needed.
Spark Plug:
Inspect every 10-15 hours, replace as needed. Recommended plug: NGK BR9EG or equivalent.
Chain Adjustment:
Check and adjust chain slack regularly, every few rides. Proper slack: 20-30 mm (0.79-1.18 in) at the midpoint of the lower chain run.
Engine Oil:
API GL-4 or GL-5, SAE 10W-40 motorcycle gear oil (e.g., Kawasaki Genuine Gear Oil, Motul Gear 300).
Fork Oil:
Show Oil SAE 0W or SAE 5W (e.g., Kawasaki KSSO 0W, Motul Factory Line 0.5W). Specific volume per fork leg is crucial and detailed in manual.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Coolant:
Pre-mixed ethylene glycol-based coolant with a 50/50 ratio of antifreeze and distilled water.
Power Valve:
The KIPS power-valve system can accumulate carbon deposits, leading to sticking or reduced performance. Regular cleaning is essential.
Clutch:
Clutch wear is common with aggressive riding. Regular inspection of plates and springs is recommended. Ensure correct clutch free play.
Suspension Seals:
Front fork seals can leak over time and with hard use. Replacement of seals and oil is a common maintenance task.
Carburetor Jetting:
Carburetor jetting can be sensitive to altitude, temperature, and modifications. Proper jetting is critical for optimal performance and engine longevity.
Kawasaki Offroad:
Kawasaki has a long and successful history in motocross racing, with the KX line being a cornerstone of their performance dirt bike offerings.
Kx250 Development:
The 2003 model represents an evolution of Kawasaki's KX250 platform, featuring refinements to the chassis, suspension, and engine performance to remain competitive.
Manufacturing Location:
Japan
Market Availability:
North America, Europe, and other global markets.
