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Numerous refinements to the liquid-Engine/Transmission
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Head gasket changed from metal gasket to O-rings for improved sealing and more accurate deck height
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New intake design features a single port with modified length and angle for improved intake efficiency
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Scavenging port exit angle is changed for improved scavenging efficiency, and the crankcase mating area around the scavenge ports has been increased.
Third scavenging port also modified for improved flow
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New reed valve angle, air guide and reed block are changed for improved throttle response
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Intake air duct is reshaped to suite revised intake manifold
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New expansion chamber dimensions and improved construction (changed from four-piece to a three-piece) contributes to improved engine performance
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Redesigned piston uses new rings and new piston sealing grooves to prevent ring snagging; stronger pin boss improves durability
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Clutch release shaft and lever modified, and release mechanism moved behind generator cover
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Shift performance improved by using involute splines on the fifth gear and on the output shaft. A needle bearing added to the shift shaft improves shift feel
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New water pump uses new pump gear ratios and a new impellor for increased coolant circulation, plus a new water jacket around the exhaust port eliminates
the need for an external coolant hose
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Sprocket cover, governor cover, inner/outer clutch covers, and water pump cover changed to suit new crankcases
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Generator cover changed from plastic to magnesium for improved appearance and increased functionality
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Revised carburetor settings contribute to improved throttle response, and a new carb holder allows straighter incoming airflow
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Radiator core length increased (from 220 to 240 mm) for improved cooling performance
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Upgraded ignition system features increased condenser capacity and a generator with a built-in regulator for light weight. Stator shape changed, and
new wiring harness used. Ignition timing changed to suit new power characteristics
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New, shorter spark plug eases maintenance and weighs less
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New, lightweight ignition coil is more compact
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Ignition coil primary terminals feature waterproof couplers for increased reliability
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Low-friction throttle barrel also reduces throttle operating friction
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Stainless throttle cable wire with a greater number of thinner strands delivers superb, low-friction throttle operation
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Clutch cable outer liner changed from polyethylene to Teflon for reduced friction
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Clutch adjuster added to clutch lever perch
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New front brake lever has better feel
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Steering rake reduced to 26 degrees to quicken steering response
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Footpegs are wider and offer better grip; shorter transverse length means greater cornering clearance
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Wider handlebar mounts (increased from 90 to 98 mm) help prevent handlebar bending
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New lightweight DID front rims with lightweight spokes and nipples reduce unsprung weight
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New cross-section for rear rims also designed for light weight
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Light fork and shock mounting bolts and a new rear brake master cylinder with a unitized reservoir and shorter yoke (17.5 mm shorter than '04 KX250)
contribute to light weight
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Fork mounting bolt locations changed on the top triple clamp for easier maintenance and stronger mounting
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New front brake pad material offers better feel and performance
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Chain guide roller now uses two bearings for greater durability
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Rear subframe has larger forged upper mounting brackets for improved durability
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Fuel tank filler outlet is increased form 37 to 46mm for easier fueling
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Carburetor tuning parts
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Ignition rotors with different inertial weights
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Larger 14T front sprocket
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Spark plugs of varying heat ranges
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20-inch front wheel
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Solid brake discs
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Aluminum and steel rear sprockets
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Different fork and shock springs
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Steel spoke nipples
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Front and rear wheel assemblies |
