Top 20 2003 kawasaki KX 250 Questions & Answers

burn out silencer packing or exaust leaks can burn a sparkplug , i guess your exaust system have lots of leaks that make the sparkplug fool and burn

running out of oil or low oil pressure

as long as your sprocket and brakes line up . should be good to go. we have two of the bikes

Just cause the piston looks fine dosent mean the rings are still good did you do a compression test if you don't have one buy one they are great to have with 2 stroke bikes put the cylinder head back on and cover spark plug hole with finger it should first **** a bit then should blow finger off the hole the compression should be greater than 120 psi of a 125 not sure on the 250 rule of thumb if you have less than 120 your piston or rings is pooched..

Try a .162 main jet,48 power jet,carb on 3 or 4th clip to the main jet.
Some boyser power reeds might help also about atotal of 60 to 75 bucks for the whole deal and that should get you to bonzai state in no time.

Go to this website to see an exploded diagram of your carb; www.babbittsonline.com

The VIN listed is backwards, should read JKAKXMK13SA009008. Bike was made in Japan in 1995

Just remove the right side cover to expose the kick start mechanism. Remove the bolt on the end of the shaft, tow washers and guide then the spring. It has been awhile since I worked on the KX 250, but as I recall, the clutch does not need to be removed in the process of replacing the spring. I could be wrong on that. Below is the kick mechanism on your bike. Please rate my answer. Thanks.

I believe the arm is on top of the case on the left hand side attached to a shaft that goes into the case. It also may have a bolt in the side of the case below the arm that has a machined shoulder on it to retain the shaft from pulling out. If it does, remove it.If this is the way it's set up, it actuates the clutch thru a rod that goes all the way across the motor inside the hollow shaft that the clutch is mounted on. I don't have specific experience to the 250 KX, but I've been in the little ones and that's the way they're set up. So here's what you do-
Drain the gear oil and remove the round clutch cover on the right side of the bike. Remove the 5 or 6 washered bolts and the springs from the clutch pressure plate. Remove the pressure plate and you'll see the clutch lifter-it's a short rod with a flat bearing on it located in the middle of the clutch shaft. Remove it and using a small magnet tool go inside the hollow shaft and retrieve the actuating rod. There may be a ball bearing with it as well, although I don't think there is in that bike. Anyway, don't lose it if it has one and pay attention to which end of the shaft goes to the clutch arm. You can now replace the arm. When your putting it back together, rotate the arm with your fingers and make sure the lifter is moving up and down before you put the pressure plate and springs back in. Good luck!

it sounds like the float,in the carb is stuck,,so not stopping fuel as it fills.....give it a tap on the bottom of the carb if no joy take off and clean,,,

Technicaly it is designated " Lever-comp-change shaft ". Ask the parts counter for that and they will kinda look at you funny. Generally they are called a " shift shaft ". Your Kawasaki dealer should have one or you can go online to Babbitt's and get one there. www.babbittsonline.com

There should be a allen key plug to take out of the caliper then once this is out there will be another allen key head behind the plug to undo (this is the pin) just undo, take out and the pads should be able to be removed.
Pay close attention to the direction pads come out and any spacers between the pads and brake piston as you want them all back in exactly the same with the new pads they stop the pads from rattling around when riding
good luck regards Jamie

If the bike is real bouncy with no dampining you need to have shock rebuilt you cant just add oil to fix.Most rear mono shocks have a little bottle of nitrogen gas on side of shock.When shock seals go bad the oil and gas leaks out. Most times it is cheaper to find shop to rebuild shock then buying new one.Mono shocks can run anywhere from 250.00 to 500.00$.you can get rebuilt for about 100.00 to 150.00$ depending on parts needed.

did u take out your jets out & poke wire through them. i had one that had green goo that didn't blow out with air, had to poke it out

603 ml per fork

http://www.repairmanualclub.com/motomanuals/index.php

Insert a screw driver to the carb's adjuster screw. Turning clockwise will increase the flow and turning counter clockwise will reduce the flow.