🏷️ Basic Information

Make:

Kawasaki

Model:

KX250R1

Year:

2005

Vin Range North America:

JKAKX250RRA000001 AND UP

Vin Range Australia:

JKAKXMRC#5A000001 AND UP

👋 Introduction

Market Segment:

The Kawasaki KX250R1 was a highly competitive motocross machine in the mid-2000s, known for its performance and race-bred heritage.

Key Competitors:

Competed directly with Yamaha YZ250, Honda CR250R, and Suzuki RM250 of the same model year.

Bike Description:

The 2005 KX250R1 was a 2-stroke, liquid-cooled, motocross competition motorcycle, a staple in amateur and professional racing circuits.

Utility For Owners:

Essential for owners performing maintenance, repairs, or simply understanding their machine. Critical for sourcing correct OEM replacement parts.

📋 Manual Details

Coverage:

Complete parts list for the 2005 Kawasaki KX250R1 motocross motorcycle.

Page Count:

Not specified in provided information. Typically, parts manuals for this era range from 150-300 pages.

Manual Type:

Parts Manual / Parts Catalog

Language:

English (standard for Kawasaki manuals of this era, especially for North American and Australian markets).

Format:

Illustrated Parts List with Exploded Views. Likely available in print and potentially digital (PDF) formats.

📖 Manual Coverage

Engine Assembly:

Detailed breakdown of all engine components, including cylinder, piston, crankshaft, connecting rod, valves, camshaft, ignition system, carburetor, and cooling system parts.

Transmission Drivetrain:

Comprehensive parts listing for the gearbox, clutch assembly, shift mechanism, and final drive components (sprockets, chain).

Chassis Frame:

Exploded views of the frame, sub-frame, swingarm, linkage system, and associated hardware.

Suspension Front:

Parts breakdown for the front fork assembly (fork tubes, sliders, seals, springs, damping components).

Suspension Rear:

Detailed parts list for the rear shock absorber, linkage, and swingarm pivots.

Wheels Brakes:

Component breakdown for front and rear wheels, hubs, spokes, tires, brake calipers, master cylinders, brake lines, rotors, and brake pads.

Fuel System:

Parts for the fuel tank, petcock, fuel lines, and carburetor (as part of engine section).

Exhaust System:

Components for the exhaust header pipe, silencer, and associated mounting hardware.

Electrical Components:

Diagrams and part numbers for ignition coil, spark plug, wiring harness, CDI unit, stator, and any lighting components if applicable.

Controls Levers:

Parts for handlebars, grips, throttle assembly, clutch lever, brake lever, and control cables.

Bodywork Plastics:

Illustrations and part numbers for fenders, radiator shrouds, side panels, seat, and fuel tank cover.

Disassembly Assembly Aid:

Provides exploded views that are crucial for guiding the disassembly and reassembly of components. Aids in identifying the correct order and orientation of parts.

Part Identification:

Enables precise identification of every single part via its unique part number, essential for ordering replacements and ensuring correct fitment.

Troubleshooting Part Replacement:

While not a diagnostic manual, it's indispensable for identifying worn or damaged parts during troubleshooting and for specifying replacements.

Depth:

Highly detailed for part identification and visual assembly guidance. It focuses on 'what' part goes 'where' and its corresponding number, rather than 'how' to perform a complex repair. It's a critical adjunct to a full service manual.

📊 Manual Specifications

Digital Format Quality:

Assuming a PDF format, quality would typically be high-resolution scans suitable for printing and digital viewing, with searchable text if OCR was applied.

Print Quality:

For physical copies, expect professional printing on quality paper stock, with clear, sharp images and legible text.

Binding Type:

Typically coil-bound or perfect-bound for ease of lay-flat use in a workshop environment.

Paper Type:

Durable, often glossy or semi-gloss paper to withstand workshop conditions and ensure clarity of exploded diagrams.

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder.

Displacement:

249 cc (approximate).

Bore X Stroke:

Typically around 66.4 mm x 72.0 mm for this era's 250cc Kawasaki models.

Fuel Induction:

Carburetor (likely Keihin PWK38).

Horsepower Estimate:

Estimated 45-50+ HP at peak RPM (actual figures vary based on tuning and specific model iterations).

Torque Estimate:

Estimated 30-35 lb-ft at peak torque (actual figures vary).

Fuel Type:

Unleaded gasoline, mixed with 2-stroke oil (ratio typically 30:1 or 50:1 depending on oil type and manufacturer recommendation).

Coolant Type:

Proprietary Kawasaki coolant or equivalent. Mixture of distilled water and ethylene glycol based antifreeze.

🔧 Transmission

Transmission Type:

5-speed, constant mesh.

Clutch Type:

Wet, multi-disc.

Final Drive:

Chain drive.

Transmission Oil Type:

API GL-4, SAE 80 or 10W-40 motorcycle gear oil.

📐 Dimensions

Overall Length:

Approximately 2155 mm (84.8 in).

Overall Width:

Approximately 820 mm (32.3 in).

Overall Height:

Approximately 1250 mm (49.2 in).

Wheelbase:

Approximately 1465 mm (57.7 in).

Dry Weight:

Approximately 92.3 kg (203.5 lbs).

Fuel Capacity:

8.0 L (2.1 US gal).

Front Tire Size:

80/100-21 51M.

Rear Tire Size:

100/90-19 57M.

Wheel Bolt Pattern:

Not applicable for spoked wheels, uses axle nuts and bearings.

🛡️ Safety Features

Safety Certification:

Off-road competition motorcycles are not typically safety certified for road use; designed for closed-course racing environments.

Braking System Front:

Hydraulic disc brake.

Braking System Rear:

Hydraulic disc brake.

Frame Construction:

High-tensile steel perimeter frame for rigidity and durability.

💡 Technology Features

Infotainment System:

Not applicable. Motocross bikes focus on performance and rider control, not infotainment features.

Driver Assistance Features:

Not applicable. Focus is on manual rider input and control.

Connectivity Features:

Not applicable.

Ignition System:

Digital CDI (Capacitor Discharge Ignition) for precise spark timing.

Power Valuation:

The KIPS (Kawasaki Integrated Power-valve System) is a key technology that optimizes power delivery across the rev range, a hallmark of Kawasaki 2-stroke engines.

🔧 Maintenance

Oil Change Frequency:

Frequent oil changes required for the 2-stroke engine's gearbox, typically after every 10-15 hours of riding or annually, depending on usage.

Air Filter Cleaning:

Requires regular cleaning and re-oiling, often after every few riding sessions, especially in dusty conditions.

Spark Plug Inspection:

Regular inspection and replacement as needed based on performance and fouling.

Coolant Capacity:

Approximately 0.6 L (0.63 US qt).

2 Stroke Oil Type:

High-quality, Jaso FD or ISO-L-EGD certified 2-stroke engine oil.

Common Wear Items:

Clutch plates, piston rings, bearings (wheel, steering head, swingarm, linkage), fork seals, brake pads, and spark plugs are common wear items on motocross bikes of this age.

Carburetor Tuning:

Carburetor jetting may need adjustment based on altitude, temperature, and modifications.

Clutch Cover Gasket Example:

Part number example (likely): 11061-0179 (This is a hypothetical example, actual part number would be in the manual).

Air Filter Example:

Part number example (likely): 11013-0028 (This is a hypothetical example).

📚 Vehicle History

Kawasaki Motorsports:

Kawasaki has a long and successful history in off-road racing, particularly with its KX line of motocross bikes.

Kx Series Development:

The KX250 has undergone continuous development, with major revisions occurring in preceding years, leading to the 2005 model's advanced features.

Manufacturing Location:

Typically manufactured in Japan.

Model Variants:

The 'R1' designation specifies the model year and variant for 2005.

🏆 Awards & Recognition

Motocross Magazine Awards:

Kawasaki KX models consistently received praise and 'bike of the year' awards from motocross publications during this era for their performance and handling.

Performance Handling Reviews:

Generally lauded for strong engine power and capable suspension and chassis dynamics, making it a top choice for serious racers.