2004–2006 Kawasaki KX250F Factory Service Manual (PN 99924-1324-02)

This factory service manual covers the Kawasaki KX250F, model KX250–N1, with European-model specification differences. Publication P/N 99924-1324-02 is the Second Edition dated January 16, 2004.

The file includes an added Suzuki RM-Z 250 cover labeled 2004–2006; the workshop procedures and model-application section are Kawasaki KX250F documentation.

• Engine repair: Engine removal, cylinder-head service, valve-clearance adjustment, camshaft timing, valve-guide replacement, and piston and cylinder inspection.

• Clutch and transmission: Wet multi-disc clutch service, external shift-mechanism repair, crankcase separation, transmission-shaft assembly, and shift-fork wear checks.

• Fuel system: Keihin FCR37 carburetor disassembly, fuel-level inspection, accelerator-pump timing, hot-start cable service, and air-cleaner maintenance.

• Cooling and lubrication: Cooling-system pressure testing, radiator-cap inspection, water-pump repair, oil-pump service, and engine oil-pressure measurement.

• Suspension: Upside-down telescopic fork overhaul, rear shock absorber service, damping adjustment, and New Uni-Trak linkage inspection.

• Brakes and chassis: Caliper and master-cylinder service, brake bleeding, wheel-bearing replacement, final-drive inspection, steering-bearing service, and frame inspection.

• Electrical diagnosis: Digital AC-CDI ignition testing, magneto checks, throttle-sensor adjustment, wiring diagrams, and an ignition troubleshooting flowchart.

Written primarily for trained mechanics in a properly equipped shop, the manual also supports owners doing basic maintenance and repair who understand mechanics, tool use, and workshop procedures.

Valve Train, Crankcase and Transmission Repair

The engine chapters cover compression testing and diagnosis, automatic decompressor service, camshaft-bearing inspection, and valve-seat repair. Valve-clearance adjustment includes shim-selection information, while piston and ring inspections distinguish standard dimensions from service limits.

The non-return camshaft-chain tensioner has specific handling cautions: improper loosening and retightening can damage the tensioner and chain.

Crankcase assembly includes separate bolt-sequence illustrations for the documented engine serial break. The transmission exploded view identifies gear order, washers, collars, and shift-fork orientation. Special tools include Crankcase Splitting Tool Assembly 57001–1362 and Crankshaft Jig 57001–1174.

Crankshaft disassembly and reassembly require a shop with the necessary tools and equipment to maintain the specified tolerances.

FCR37 Carburetor, Cooling and Oil Circulation

Carburetor coverage extends to the float valve, jet needle, throttle-valve plate, accelerator-pump diaphragm, and hot-start plunger. Inspection criteria address wear and damage, with separate procedures for fuel-level adjustment and accelerator-pump timing.

Cooling-system service covers leak testing, flushing, radiator inspection, and water-pump shaft seals and bearings. The lubrication chapter explains the separate crankcase and transmission oil chambers used by the semi-dry sump system.

The Lubrication System Chart traces the feed and scavenging circuits, filter chamber, piston oil nozzle, and transmission oil shower. The oil-filter replacement section warns that reversed installation blocks oil flow and can cause engine seizure.

Forks, Uni-Trak Linkage and Chassis Service

Fork procedures include seal and guide-bushing replacement, cylinder removal, oil-level adjustment, and spring inspection. European-model differences are identified in the front-fork damping specifications.

Rear suspension coverage includes shock oil service, spring replacement, and inspection of the swingarm, tie-rod, and rocker-arm bearings. Brake sections cover piston seals, master-cylinder cups, disc wear, and hydraulic bleeding.

The Periodic Maintenance Chart organizes recurring work. Cable, Wire, and Hose Routing drawings show the installation paths for controls, electrical leads, cooling hoses, and brake lines. Reference tables also cover transmission ratios, suspension oil quantities, tire pressures, and unit conversions.

Ignition Tests and Fault Isolation

The electrical chapter provides magneto output and stator-resistance tests, ignition-coil checks, and peak-voltage tests for the crankshaft sensor and ignition supply coils. Throttle-sensor inspection includes input/output checks and position adjustment.

The ignition troubleshooting flowchart connects test results with wiring, coil, sensor, and CDI checks, helping narrow an ignition fault before replacing components. The appendix adds symptom-based troubleshooting for starting, poor running, overheating, clutch operation, shifting, and handling.

Follow the manual’s precautions for combustible fuel, ignition high voltage, and pressurized shock-absorber service.

A Preview of Valve-Clearance and Cooling Specifications

For KX250–N1, the valve-clearance inspection specifies 0.10–0.15 mm at the inlet and 0.17–0.22 mm at the exhaust, with the engine cold at room temperature.

The cooling section lists total coolant capacity as 1.20 L and the radiator-cap relief-pressure range as 93–123 kPa. These specifications accompany the coolant-service and cap-inspection procedures.

Searchable Text, Chapter Bookmarks and PDF Contents

Text navigation and diagram detail: The service text is searchable, and embedded bookmarks cover all 17 chapters and numerous procedures. Text within some diagrams and the added cover is not searchable. Small wiring color codes are best read with zoom; the wiring diagram and ignition troubleshooting chart remain legible when enlarged.

One printable PDF contains 358 pages: the 356-page Kawasaki service manual, including nine blank pages, plus one added Suzuki cover and one additional reference page. All are included in the total.