Target Audience:
DIY motocross enthusiasts, independent repair shops, and Kawasaki service technicians.
Purpose:
To provide authoritative, manufacturer-level repair and maintenance information for the KX250 model.
Comparison Point:
Offers more detail and accuracy than generic aftermarket repair guides.
Accuracy:
Based on original factory specifications and procedures.
Comprehensiveness:
Covers all aspects of the motorcycle's mechanical and electrical systems.
Usability:
Organized for ease of reference with clear language and illustrations.
Engine:
Complete disassembly, assembly, troubleshooting, and repair of the 2-stroke engine.
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel tank and line maintenance.
Ignition System:
CDI system, spark plug specifications, troubleshooting ignition faults.
Cooling System:
Radiator, hoses, and coolant specifications for liquid-cooled engine.
Transmission:
Gearbox disassembly, assembly, inspection, and lubrication.
Clutch:
Clutch plate replacement, clutch lever adjustment, hydraulic clutch system (if applicable).
Suspension:
Front fork (USD) disassembly, assembly, oil levels, and pressure adjustments; rear shock absorber rebuild and settings.
Brakes:
Front and rear brake caliper overhaul, master cylinder service, brake pad replacement, fluid specifications (DOT 4).
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, spoke tensioning.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, troubleshooting electrical faults.
Frame Chassis:
Frame inspection, steering head bearing service, swingarm bearing maintenance.
Bodywork:
Fairing removal and installation, seat, fenders, and fuel tank component service.
Basic Maintenance:
Regular checks, lubrication points, filter cleaning/replacement, chain adjustment.
Intermediate Repair:
Component replacement (e.g., brake pads, clutch plates, wheel bearings), fluid changes.
Advanced Rebuild:
Full engine disassembly and reassembly, carburetor rebuilding, suspension fork and shock rebuild.
Troubleshooting:
Diagnostic procedures for common starting, running, and performance issues.
Adjustment:
Carburetor jetting, ignition timing, clutch and throttle cable free play, suspension sag.
Specifications:
Torque specifications for all fasteners, measurement tolerances, wear limits.
Depth Level:
Comprehensive, from basic checks to complete engine rebuilds and chassis overhauls.
Diagrams Illustrations:
Detailed exploded diagrams and step-by-step illustrations for component assembly and disassembly.
Diagnostic Charts:
Troubleshooting charts organized by symptom for efficient problem diagnosis.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
249 cc (15.19 cu in)
Bore X Stroke:
66.4 x 72.0 mm (2.61 x 2.83 in)
Horsepower Est:
Approx. 44-46 HP (at crank, manufacturer figures vary slightly by region)
Torque Est:
Approx. 27-29 lb-ft (at crank)
Carburetor:
Keihin PWK39, Single
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended.
Fuel Mixture:
2-stroke engine oil mixed with gasoline at 30:1 or 50:1 ratio (refer to manual for precise specification).
Lubrication Type:
Premix or Oil Injection (confirm model variation, though 2006 KX250 typically used premix).
Transmission Type:
5-speed constant mesh, sequential manual
Gear Ratios:
Specific ratios detailed in manual (e.g., 1st: 2.462, 2nd: 1.765, 3rd: 1.400, 4th: 1.150, 5th: 0.960 - typical for this model).
Optional Gearing:
Aftermarket sprockets and chain kits available, but not factory options.
Clutch Type:
Wet, multi-disc
Transmission Oil Spec:
Kawasaki especific transmission oil or equivalent SAE 10W-30 API SE, SF, or SG.
Oil Change Transmission:
Every 6-10 hours of riding or annually, whichever comes first (refer to manual for precise interval).
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Chain Lubrication Adjustment:
Every ride or every 500 miles (800 km).
Spark Plug Replacement:
Inspect every 5-10 hours, replace as needed.
Top End Rebuild:
Highly dependent on riding style and conditions, typically every 20-40 hours for competitive use.
Engine Oil Type:
2-stroke premix oil (e.g., Motul 800, Yamalube 2R) mixed with gasoline.
Coolant Type:
Kawasaki Coolant or equivalent ethylene glycol-based coolant with distilled water (50/50 mix).
Power Valve Sticking:
Common in 2-strokes if not regularly cleaned and serviced due to carbon buildup.
Carburetor Jetting:
Can be sensitive to altitude and temperature changes, requiring tuning.
Clutch Wear:
Clutch plates can wear depending on riding style and frequency of use.
Suspension Seals:
Fork and shock seals can leak over time and require replacement.
Kawasaki Legacy:
Kawasaki has a long and successful history in motocross racing with the KX line, dating back to the 1970s.
Kx250 2006 Context:
The 2006 model represents a refinement of the second-generation KX250, featuring improvements based on racing feedback.
Predecessor Features:
Continued the legacy of strong, tractable power delivery characteristic of Kawasaki's 2-stroke motocross bikes.
Production Period:
The KX250 2-stroke was produced for many years, with significant updates in the mid-2000s leading up to the discontinuation of the 2-stroke model.
