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Kawasaki · Two-stroke, premix, chain drive

KX 250

Library entry covers 1990-2008, 2-stroke

51 factory 54 guideline

Published source

Kawasaki KX250 (KX250-R) 2005-2008 Service Manual, Periodic Maintenance Chart pp.2-3 to 2-4

Factory service manual. Covers KX250-R 2005-2008 service manual; chart columns are races with hours printed in the headers.

105 items for a 1997 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1997 Kawasaki KX 250

On the road: every 150 mi

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,000 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,000 mi or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 3,000 mi or 12 months

12 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,000 mi or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 6,000 mi or 12 months

7 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

1 item

Change gearbox oil

Primary and gearbox

Guideline

Every 8,000 mi or 2 years

1 item

Replace spark plugs

Engine

Guideline

Every 10,000 mi or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 12,000 mi or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 2.5 h

34 items

Coolant (check)

Engine

Factory

Factory: each race (or 2.5 hours)
Cooling hoses and connections (inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Cylinder head, cylinder (inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Engine sprocket (inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Exhaust valve (clean and inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
General lubrication (perform)

Engine

Factory

Factory: each race (or 2.5 hours)
Kick pedal and shift pedal (clean)

Engine

Factory

Factory: each race (or 2.5 hours)
Muffler (clean and inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Nuts, bolts, fasteners (inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Piston and piston ring (clean and inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Rear sprocket (inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Reed valve (inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Small end bearing (inspect)

Engine

Factory

Factory: each race (or 2.5 hours)
Spark plug (clean, gap)

Engine

Factory

Factory: each race (or 2.5 hours)
Air cleaner element (clean)

Fuel and air

Factory

Factory: each race (or 2.5 hours)
Carburetor (inspect and adjust)

Fuel and air

Factory

Factory: each race (or 2.5 hours)
Fuel hose, connections (inspect)

Fuel and air

Factory

Factory: each race (or 2.5 hours)
Clutch (adjust)

Primary and gearbox

Factory

Factory: each race (or 2.5 hours)
Clutch and friction plates (inspect)

Primary and gearbox

Factory

Factory: each race (or 2.5 hours)
Drive chain (adjust)

Final drive

Factory

Factory: each race (or 2.5 hours)
Drive chain (lubricate)

Final drive

Factory

Factory: each race (or 2.5 hours)
Drive chain wear (inspect)

Final drive

Factory

Factory: each race (or 2.5 hours)
Front fork (inspect and clean)

Front end

Factory

Factory: each race (or 2.5 hours)
Steering play (inspect)

Front end

Factory

Factory: each race (or 2.5 hours)
Frame (clean and inspect)

Rear suspension and frame

Factory

Factory: each race (or 2.5 hours)
Rear shock absorber (inspect)

Rear suspension and frame

Factory

Factory: each race (or 2.5 hours)
Brake adjustment (inspect)

Brakes

Factory

Factory: each race (or 2.5 hours)
Brake fluid level (inspect)

Brakes

Factory

Factory: each race (or 2.5 hours)
Brake hoses, connections (inspect)

Brakes

Factory

Factory: each race (or 2.5 hours)
Brake pad wear (inspect)

Brakes

Factory

Factory: each race (or 2.5 hours)
Spoke tightness and rim runout (inspect)

Wheels and tires

Factory

Factory: each race (or 2.5 hours)
Wheel bearing (inspect)

Wheels and tires

Factory

Factory: each race (or 2.5 hours)
Wheel/tire (air pressure, wear, damage) (inspect)

Wheels and tires

Factory

Factory: each race (or 2.5 hours)
Throttle cable (adjust)

Controls and cables

Factory

Factory: each race (or 2.5 hours)

Every 7.5 h

7 items

Muffler packing (change)

Engine

Factory

Factory: every 3 races (or 7.5 hours)
Piston and piston ring (replace)

Engine

Factory

Factory: R every 3 races (or 7.5 hours)
Spark plug (replace)

Engine

Factory

Factory: R every 3 races (or 7.5 hours)
Fuel system (clean)

Fuel and air

Factory

Factory: every 3 races (or 7.5 hours)
Transmission oil (change)

Primary and gearbox

Factory

Factory: every 3 races (or 7.5 hours)
Swing arm and Uni-Trak linkage pivots (grease)

Rear suspension and frame

Factory

Factory: every 3 races (or 7.5 hours)
Swing arm and Uni-Trak linkage pivots (inspect)

Rear suspension and frame

Factory

Factory: every 3 races (or 7.5 hours)

Every 15 h

3 items

Front fork oil (change)

Front end

Factory

Factory: every 6 races (or 15 hours)
Steering stem bearing (grease)

Front end

Factory

Factory: every 6 races (or 15 hours)
Rear shock oil (replace)

Rear suspension and frame

Factory

Factory: every 6 races (or 15 hours)

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

7 items

Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake caliper fluid seal and dust seal (replace)

Brakes

Factory

Factory: every 2 years
Brake fluid (change)

Brakes

Factory

Factory: every 2 years
Brake master cylinder cup and dust cover (replace)

Brakes

Factory

Factory: every 2 years
Replace brake fluid

Brakes

Guideline

Every 4 years

5 items

Fuel hose (replace)

Fuel and air

Factory

Factory: every 4 years
Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Brake hoses and pipe (replace)

Brakes

Factory

Factory: every 4 years
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

2 items

Air cleaner element (replace)

Fuel and air

Factory

Factory: if damaged
Chain slipper and guide (replace)

Final drive

Factory

Factory: if damaged

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.