🏷️ Basic Information

Make:

Kawasaki

Model:

KX250

Year:

2004

Type:

Motocross Competition Motorcycle

Engine Code Family:

2-Stroke Single Cylinder

👋 Introduction

Category:

Professional Motocross Racing

Target User:

Motocross racers, mechanics, and dedicated DIY enthusiasts.

Segment:

250cc 2-stroke motocross class.

Key Competitors:

Yamaha YZ250, Suzuki RM250, Honda CR250R.

Performance Focus:

Designed for peak performance in demanding off-road competition.

Manual Purpose:

To empower owners and technicians with the knowledge to maintain and repair the KX250 to factory specifications.

📋 Manual Details

General Coverage:

Complete service, repair, maintenance, troubleshooting, and diagnostics for the 2004 Kawasaki KX250.

Specific Systems:

Engine, Fuel System, Lubrication System, Cooling System, Transmission, Clutch, Ignition System, Electrical System, Frame, Suspension (Front and Rear), Brakes (Front and Rear), Wheels, Tires, Bodywork, Controls, Tools, Torque Specifications, Troubleshooting Guides.

Estimated Pages:

Approximately 300-400 pages (typical for factory service manuals of this era).

Type:

Factory Service Repair Manual (FSM)

Primary Language:

English

Digital Format:

PDF (Searchable, Printable)

📖 Manual Coverage

Engine Disassembly Assembly:

Complete breakdown and reassembly of the 2-stroke engine, including cylinder, piston, crankshaft, connecting rod, bearings, seals, and gaskets.

Fuel System Details:

Carburetor identification, disassembly, cleaning, adjustment (jetting, float height), fuel tank maintenance, fuel lines.

Transmission And Clutch:

Gearbox inspection, shift drum and fork service, clutch assembly (plates, springs, hub), clutch cable adjustment and replacement.

Ignition And Electrical:

CDI unit testing, stator and rotor inspection, spark plug specifications, lighting system (if applicable), wiring diagrams.

Suspension And Chassis:

Front fork disassembly, seal replacement, oil levels and viscosity, rear shock absorber servicing, linkage lubrication.

Brake System:

Front and rear brake caliper service, piston seal replacement, brake pad inspection and replacement, brake fluid specifications and bleeding procedures.

Routine Maintenance:

Oil changes, air filter cleaning/replacement, spark plug inspection, chain adjustment, bolt torque checks, coolant checks (if liquid-cooled).

Troubleshooting Guides:

Systematic diagnostics for common problems such as starting issues, poor performance, overheating, clutch slippage, brake fade.

Repair Procedures:

Step-by-step instructions for component removal, installation, rebuilding, and replacement across all major vehicle systems.

Adjustment Procedures:

Carburetor, clutch, throttle, and brake lever adjustments.

Diagnostic Level:

Advanced diagnostic procedures, including electrical testing with multimeters and checking engine compression.

Rebuild Scope:

Complete engine and transmission rebuilds, suspension overhauls, and brake system overhauls.

Special Tools:

Identification of required specialized tools for specific repair and maintenance tasks.

📊 Manual Specifications

Type:

PDF

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable pages for on-the-bench use.

Image Clarity:

High-resolution diagrams, illustrations, and photographs.

Digital Binding:

N/A (Digital Format)

Digital Paper Simulation:

N/A (Digital Format)

⚙️ Engine Specifications

Configuration:

Liquid-cooled, 2-stroke, single-cylinder

Bore X Stroke:

66.4 mm x 72.0 mm

Displacement:

249 cc (250cc class)

Compression Ratio:

9.5:1 (typical, may vary slightly)

Ignition:

Digital CDI

Horsepower Estimated:

Approximately 45-50 HP (stock, at crank)

Torque Estimated:

Approximately 28-30 lb-ft (stock, at crank)

Carburetor Model:

Keihin PWK38 (38mm flat slide)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Premix Ratio:

50:1 or 40:1 with high-quality 2-stroke racing oil (refer to manual for exact specification).

🔧 Transmission

Type:

5-speed constant mesh

Availability:

N/A (single transmission option for this model year)

Clutch Type:

Wet multi-disc

Gear Ratios:

Detailed in manual (e.g., 1st: 2.467, 2nd: 1.778, 3rd: 1.400, 4th: 1.136, 5th: 0.913).

Transmission Oil Type:

API GL-4 SAE 10W-30 gear oil (Kawasaki brand recommended).

Transmission Oil Capacity:

Approximately 0.7 Liters (check manual for precise measurement procedure).

📐 Dimensions

Length:

Approx. 2160 mm (85.0 in)

Width:

Approx. 820 mm (32.3 in)

Height:

Approx. 1260 mm (49.6 in)

Wheelbase:

Approx. 1470 mm (57.9 in)

Ground Clearance:

Approx. 350 mm (13.8 in)

Seat Height:

Approx. 970 mm (38.2 in)

Dry Weight:

Approx. 93 kg (205 lbs)

Curb Weight:

Approx. 102 kg (225 lbs) (with all necessary fluids)

Fuel Tank Capacity:

8.0 Liters (2.1 US gal)

🛡️ Safety Features

Crash Test Ratings:

N/A (Competition motorcycles are not subject to typical road vehicle safety testing).

Brakes:

Hydraulic disc brakes front and rear for superior stopping power.

Suspension:

High-performance, adjustable suspension (Kayaba) for stability and control.

Frame Construction:

Strong and lightweight perimeter frame for chassis rigidity.

Ergonomics:

Designed for optimal rider control and positioning during aggressive riding.

💡 Technology Features

Availability:

N/A (Competition motocross motorcycle, no infotainment features).

Features:

N/A (Focus is on rider control and mechanical performance).

Features:

N/A (No electronic connectivity features).

System:

Analog ignition system with CDI control for ignition timing.

🔧 Maintenance

Oil Change Frequency:

Every 5-10 hours of riding or annually, whichever comes first (refer to manual for specific conditions).

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions.

Spark Plug Inspection:

Every 10-15 hours of riding.

Top End Rebuild Recommendation:

Every 20-40 hours of riding for optimal performance (piston, rings, cylinder inspection).

Engine Oil Type:

High-quality 2-stroke premix oil (e.g., Motul, Maxima, Yamalube).

Coolant Type:

Pre-mixed ethylene glycol coolant with corrosion inhibitors (Kawasaki's K-Coolant or equivalent).

Brake Fluid Type:

DOT 4 brake fluid.

Common Wear Items:

Clutch plates, piston rings, wheel bearings, steering head bearings, brake pads, swingarm bearings.

Carburetor Tuning:

May require periodic adjustments based on altitude, temperature, and modifications.

Suspension Servicing:

Regular fork seal and shock oil replacement is crucial for maintaining optimal suspension performance.

📚 Vehicle History

Kawasaki Motorsports:

Kawasaki has a long and storied history in motocross racing, with a reputation for producing powerful and competitive machinery.

Kx Series:

The KX line has consistently evolved to incorporate advanced technology and performance enhancements, with the 2004 model representing a significant iteration in the development of the 250cc two-stroke.

Production Years For Model:

The KX250 was produced for many years, with the 2004 model being part of the generation that saw continuous refinement.

Manufacturing Location:

Japan (typical for Kawasaki's high-performance models).

🏆 Awards & Recognition

Motorsport Wins:

The KX250 platform has been a consistent contender and winner in professional motocross championships globally.

Industry Reviews 2004:

Generally praised for its strong engine, capable chassis, and competitive performance in its class for the 2004 model year.

Manual Certification:

Factory-issued documentation, considered the authoritative source for repair and maintenance.