2004-2005 Kawasaki KX250F Factory Service Manual (Second Edition)
Kawasaki Models Covered & Key Technical Specifications
Models: Kawasaki KX250F
Sub-models / Variants: KX250-N1
Model Years: 2004–2005
Technical Data:
- Engine displacement: 249 mL
- Engine type: 4-stroke, single cylinder, DOHC 4 valve, liquid-cooled
- Maximum horsepower: 31.6 kW (43.0 PS) @ 11,000 r/min
- Maximum torque: 28.7 N·m @ 8,500 r/min
- Transmission: 5-speed, constant mesh, return shift
- Carburetion: KEIHIN FCR37
- Fuel capacity: 7.5 L (2.0 US gal)
- Compression ratio: 12.6:1
- Ignition: Digital AC-CDI
- Spark plug: NGK CR8EB or NGK CR9EB
Kawasaki Manual Features & Content Preview
- Built for workshops and owners servicing the 2004–2005 Kawasaki KX250F (KX250-N1) motocross motorcycle, specifically covering the liquid-cooled DOHC four-stroke engine and Keihin FCR37 carburetion
- Official OEM publication, Second Edition (January 16, 2004)
- Includes 47 exploded-view component illustrations with detailed torque values, 22 specialized maintenance summaries, and comprehensive component-tolerance charts for the engine, suspension, and brake systems
- Comprehensive 356-page reference acting as the authoritative source for the KX250-N1 launch build, featuring targeted tuning data for the high-performance powerplant
Contents Summary
This documentation provides an extensive breakdown of the KX250F. It kicks off with fundamental shop safety, model identification, and standard fastener torque values. From there, the technical coverage moves into a structured breakdown of periodic maintenance. You will find precise system inspections and required adjustments for the engine, cooling system, frame, and chassis.
Need granular specs? Later sections dig into the fuel system, top-end assembly, and drivetrain. This includes exact valve clearance parameters and crankshaft inspection criteria. Dedicated chapters also thoroughly document mechanical components like the Uni-Trak rear suspension, brake caliper rebuilds, and specific transmission gear ratios for the N1 configuration.
Technical Preview
High-precision service requires exact tolerances. As a quick reference, the exhaust valve clearance standard is listed at 0.17–0.22 mm. When checking the lubrication system, engine oil capacity is specified at exactly 1.5 liters. You will also find critical lower-end measurements, such as the connecting rod big end radial clearance, sitting at 0.002–0.014 mm.
Working on high-performance motocross engines carries inherent physical risks. Always verify your mechanical limits, use appropriate protective gear, and consult a certified technician if you are unsure about a specific drivetrain adjustment.
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