Target User:
Professional motocross mechanics, race teams, and experienced DIY motorcycle enthusiasts seeking detailed repair and maintenance guidance for the 1993 Kawasaki KX250.
Value Proposition:
Provides authoritative, factory-level technical information essential for keeping a classic motocross machine in peak condition. Offers significant cost savings over dealership service.
Essential Resource:
This manual is an indispensable resource for anyone involved in the maintenance, repair, or restoration of the 1993 Kawasaki KX250. Its comprehensive nature ensures all aspects of the machine are covered.
Diagnostic Capability:
Detailed troubleshooting sections and wiring diagrams are crucial for diagnosing and resolving issues quickly and efficiently.
General Coverage:
Comprehensive service and repair information for the 1993 Kawasaki KX250 motocross motorcycle.
Specific Systems:
Engine, transmission, chassis, suspension, brakes, electrical system, fuel system, cooling system, lubrication system, exhaust system, bodywork, troubleshooting, maintenance.
Estimated Pages:
Approximately 300-400 pages (typical for this era's service manuals).
Type:
Service Repair Manual
Primary Language:
English
Digital Format:
PDF Download
Engine Mechanical:
Engine disassembly and reassembly, piston, rings, cylinder, crankshaft, connecting rod, bearings, valve timing (if applicable, though typically 2-stroke), lubrication system.
Engine Tuning And Performance:
Carburetor tuning, jetting, ignition timing, exhaust system analysis.
Transmission Drivetrain:
Gearbox disassembly and reassembly, clutch operation and replacement, chain and sprocket maintenance.
Suspension System:
Front fork (USD type typical for this era) overhaul, rear shock absorber maintenance and adjustment, linkage systems.
Brake System:
Front and rear disc brake system maintenance, caliper overhaul, fluid replacement, pad replacement.
Electrical System:
Ignition system components (CDI, coil, spark plug), lighting (if equipped), wiring diagrams, troubleshooting electrical faults.
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor model identification and servicing (likely Keihin PWK).
Cooling System:
Liquid-cooled engine components, radiator, hoses, coolant specifications.
Routine Maintenance:
Oil changes (gearbox oil), chain lubrication and adjustment, air filter cleaning, spark plug replacement, brake adjustment, suspension setup.
Troubleshooting:
Diagnostic charts for common engine, electrical, and performance issues; identification of symptoms and causes.
Repair And Rebuild:
Step-by-step instructions for major component removal, disassembly, inspection, repair, and reassembly.
Technical Data And Specifications:
Torque specifications, clearances, gap settings, fluid capacities, electrical resistance values.
Level Of Detail:
Targets professional technicians with in-depth procedures, but provides sufficient data for dedicated DIY enthusiasts. Covers everything from basic adjustments to complete engine rebuilds.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke:
66.4 mm x 72.0 mm (typical for this generation)
Induction:
Carburetor (likely Keihin PWK 35mm)
Compression Ratio:
8.7:1 (typical, can vary with tuning)
Horsepower:
Approx. 45-50 HP (factory spec, varies with exhaust and tuning)
Torque:
Approx. 28-30 lb-ft (factory spec)
Carburetor Model:
Keihin PWK 35mm (likely)
Fuel Type:
Unleaded gasoline (91-98 octane recommended)
Fuel Mixture:
2-stroke oil pre-mix (specified ratio in manual, typically 30:1 or 40:1 depending on oil quality).
Type:
Constant-mesh, 5-speed sequential
Clutch:
Wet, multi-disc, cable operated
Gear Ratios:
Specific gear ratios detailed in the manual (e.g., 1st: 2.500, 2nd: 1.867, 3rd: 1.400, 4th: 1.130, 5th: 0.917).
Final Drive:
Chain drive (13T front, 48T rear typical)
Overall Length:
Approx. 2160 mm (85.0 in)
Overall Width:
Approx. 820 mm (32.3 in)
Overall Height:
Approx. 1260 mm (49.6 in)
Wheelbase:
Approx. 1450 mm (57.1 in)
Dry Weight:
Approx. 101 kg (222.7 lbs)
Wet Weight:
Approx. 107 kg (235.9 lbs)
Fuel Capacity:
8.5 L (2.2 US gal)
Engine Oil Change:
Every 10-15 hours of riding or after major events (refer to manual for exact specification).
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Spark Plug Replacement:
As needed, typically checked every 15-20 hours, replaced when fouled or worn.
Chain And Sprockets:
Clean and lubricate after every ride; inspect for wear and replace as a set when worn.
Transmission Oil:
Kawasaki Genuine Gear Oil SAE 80W-90 or equivalent (API GL-4). Capacity: 0.65 L (0.69 US qt).
Coolant:
Ethylene glycol-based coolant with a 50/50 mix of distilled water. Capacity: Approx. 1.4 L (1.5 US qt).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Clutch plates, piston and rings, chain and sprockets, wheel bearings, fork seals, swingarm bearings.
Carburetor Performance:
Carburetor jetting can be sensitive to altitude, temperature, and exhaust modifications; requires careful tuning.
Power Valve System:
Early power valve systems (like on this model) can require periodic cleaning and adjustment to maintain optimal performance and prevent sticking.
Kawasaki Motocross:
Kawasaki has a long and successful history in motocross racing, with the KX line being a cornerstone of their off-road performance offerings since the 1970s.
Kx250 Development:
The 1993 model represents a significant update in the KX250's evolution, likely incorporating advancements in suspension (USD forks), engine tuning, and chassis design aimed at improving competitive performance.
Manufacturing Location:
Japan
