Race Tuning 05-07 KX250

SERVICE INFORMATION
Subject Detail
Category Technical Service Information Model KX250R6F Serial No. Date TSI552 Dec. 29, 2005
KX250R6F Model Race Tuning
The following modifications increase midrange and high-speed power, making the vehicle more competitive for the experienced racer. Fig.1 Tuning Effects
Modified 1
(Cylinder tuning & compression ratio increase)
Stock (US) Modified 2

(Cylinder tuning & compression ratio decrease)
T E C H N I C A L S E R V I C E I N F O R M A T I O N
Stock (EU)
Output
Engine rpm
CAUTION Kawasaki cannot accept any responsibility for the results of the modifications described in this Service Information. Whenever the power output of an engine is increased, the reliability and durability of the engine decreases. This is especially true of competition engines, which are highly stressed even in stock form. For best results, engine modification should be made by an experienced tuner.
Page 1 of 6 Quality Division, Consumer Products & Machinery Company, Kawasaki Heavy Industries, Ltd.
Modification Procedure 1) Cylinder (see Fig.2, 3 and 4) Polish and smooth the intake, exhaust, and scavenging ports (particularly the areas in each port near the cylinder bore). Chamfer the main / sub exhaust ports as shown (Fig. 2, 3 and 4). Adjust the main/ sub scavenging ports timing to match the illustration (Fig. 2). CAUTION Maintain the original shape of the ports, and chamfer the sharp edges to prevent ring damage. Removing more material than specified may result in a loss of power. NOTE
Use a racing fuel with Research Octane Number (RON) 98 100 to help prevent abnormal combustion accompanied by increase in compression caused by this modification.
Fig. 2
(1) Exhaust Port (2) Sub-exhausting Ports (3) Scavenging Ports
(4) Sub-scavenging Ports (5) No.3 SC Port
Fig. 3
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Fig. 4
T E C H N I C A L
2) Compression ratio selection US model
Track Type Cylinder Head Carburetor Setting * Compression Ratio Hard Track P/N 11001-034(STD) STD =9.1 Normal Track Grind the head P/N 11001-034 as shown in Fig.5 MJ: 1 size up =9.3 Sand Track P/N 11001-048 (Optional) STD =8.9
* The carburetor setting above should only provide a rule of thumb. Be sure to adjust to the
proper setting after running the vehicle.
S E R V I C E I N F O R M A T I O N
Fig. 5
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EU model
Track Type Cylinder Head ** Carburetor Setting *** Compression Ratio =8.9 Normal and Hard Tracks P/N 11001-034(STD) ---------=8.6 Sand Track P/N 11001-068 (Optional) --------Deep Sand Track P/N 11001-068(Optional) MJ: 2 sizes up =8.6
**If smooth characteristics are preferred for the normal or hard track, use the cylinder head P/N
11001-0068. ***The carburetor setting above should only provide a rule of thumb. Be sure to adjust to the proper setting after running the vehicle.
3) Flywheel Magneto Rotor (Optional Parts) Five (5) optional rotors are available. The standard flywheel can be substituted with one of the optional rotors shown below to better suit the track conditions. [Table of Inertia Moment]
P/N Inertia Moment (kgcm2) Racing Conditions Increase in throttle response
21007-1425 21007-1424 21007-1429 21007-1426 21007-1427 21007-1428
4.0 4.5 4.9 5.3 5.6 5.9
Increase in rear wheel traction
4) Spark Plug Use the specified racing spark plug. Spark Plug P/N R7376-8 (NGK) 92070-1275 5) Gasoline Use an unleaded gasoline with Research Octane Number (RON) 98-100. NOTE Use of a regular or not recommended gasoline or leaner air-gasoline mixture may cause abnormal combustion or damage to engine. CAUTION Use of leaded fuel is illegal in some countries, states or territories. Check local regulations before using leaded fuel.
Carburetor Optional Parts The carburetor setting may need to be adjusted according to the track conditions, temperature, atmospheric pressure, the riders feel and other factors. The optional parts for the model KX250R6F are shown in the last page of this Service Information.
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Warranty Information This Service Information is racing support information only, not warranty authorization.
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Carburetor Setting and Optional Parts

1) Base Jetting
Markets Body ALL MJ PWJ JN CA SJ AS 1 1/2 NJ BPP Height Choke Height Well Dia. 0 mm 7.45 (With Slit) 3.6 5.0 POP BP PO 1.5 0.7 ID Mark J045A
#8.0 PWK #160 #55 NALF-2 #50 38S (2.51.0)
10.5 0.8
2) JN Optional Parts
P/No. 16187-0167 16187-0157 16187-0158 16187-0159 16187-0160 16187-0168 16187-0162 16187-0163 16187-0164 16187-0165
ID Mark NFTE F G H W NFUE F G H W
D 2.695 2.705 2.715 2.725 2.735 2.695 2.705 2.715 2.725 2.735
l1 27.60
l2 42.40
l3 47.40
1 12757
2 300
A/F Condition Richer STD (Clip Position 2nd) Leaner
27.15
41.95
46.95
12757
30 0
Richer
Leaner * NAL is richer than NAF (0.5 Clip Position).
3) CA Optional Parts
P/No. 16025-1217 16025-1215 16025-1216 Number #8(2.51.5) #6(2.51.5) #7(2.51.5) Remark STD OP OP
4) PWJ Optional Parts

P/No 16159-1053 16159-1055 16159-1054 16159-1056 16159-1057 Number #50 #52 #55 #58 #60 Remark OP OP STD OP OP
5) SJ Optional Parts
P/No. 92064-1142 92064-1143 92064-1144 92064-1130 92064-1145 Number #45 #48 #50 #52 #55 Remark OP OP STD OP OP
6) MJ Optional Parts
KHI No. 92063-1366 92063-1367 92063-1368 92063-1369 92063-1370 92063-1372 Number #155 #158 #160 #162 #165 #170 Remark OP OP STD OP OP OP
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SERVICE INFORMATION

KX250R6F Model Race Tuning

Stock (US) Modified 2

(1) Exhaust Port (2) Sub-exhausting Ports (3) Scavenging Ports

(4) Sub-scavenging Ports (5) No.3 SC Port

21007-1425 21007-1424 21007-1429 21007-1426 21007-1427 21007-1428

4.0 4.5 4.9 5.3 5.6 5.9

Increase in rear wheel traction

Carburetor Setting and Optional Parts

#8.0 PWK #160 #55 NALF-2 #50 38S (2.51.0)

ID Mark NFTE F G H W NFUE F G H W

A/F Condition Richer STD (Clip Position 2nd) Leaner

Leaner * NAL is richer than NAF (0.5 Clip Position).

4) PWJ Optional Parts

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