Kawasaki KX250F Service Manual

Kawasaki
Motorcycle
Table of Contents
  • How to use this manual

    7
  • Before Servicing

    10
  • Replacement parts

    11
  • General information

    12
  • Model Identification

    15
  • General Specifications

    16
  • Technical Information - Dual Injector

    19
  • Unit Conversion Table

    21
  • PERIODIC MAINTENANCE

    23
  • 2-2 PERIODIC MAINTENANCE

    24
  • Periodic maintenance chart

    25
  • Torque and Locking Agent

    27
  • Specifications

    32
  • Special Tools

    35
  • Periodic Maintenance Procedures

    37
  • Throttle Body Cleaning

    38
  • Idle Speed Inspection

    39
  • Air Cleaner Element Cleaning and Inspection

    40
  • Fuel Tank Clean

    42
  • Coolant Deterioration Inspection

    43
  • Water Hoses and Connections Inspection

    44
  • Valve Clearance Adjustment

    45
  • Adjustment Shims

    46
  • Cylinder Head Warp Inspection

    47
  • Piston/Cylinder Clearance Inspection

    48
  • Clutch

    49
  • Clutch Plates Inspection

    50
  • Engine Oil Change

    51
  • Oil Filter Change

    52
  • Crankshaft/Transmission

    53
  • Tires Inspection

    54
  • Drive Chain Wear Inspection

    55
  • Drive Chain Slack Inspection

    56
  • Drive Chain Slack Adjustment

    57
  • Drive Chain Lubrication

    58
  • Front fork inspection

    69
  • Rear shock absorber oil change

    85
  • Steering stem bearing lubrication

    96
  • Electrical system

    97
  • Nut, bolt, and fastener tightness inspection

    98
  • Fuel System (DFI)

    101
  • Exploded view

    105
  • Dfi system

    111
  • Dfi parts location

    120
  • Special tools and sealant

    124
  • Dfi servicing precautions

    126
  • Troubleshooting the dfi system

    127
  • Inquiries to rider

    130
  • Dfi system troubleshooting guide

    133
  • Poor running or no power at high speed

    135
  • Self-diagnosis outline

    137
  • Service code table

    141
  • Throttle sensor input voltage inspection

    147
  • Throttle sensor output voltage inspection

    149
  • Throttle sensor resistance inspection

    151
  • Water temperature sensor inspection

    166
  • Crankshaft sensor (service code)

    168
  • Gear position switch (service code)

    170
  • Gear position switch inspection

    171
  • Vehicle-down sensor output voltage inspection

    175
  • Fuel injector installation

    178
  • Fuel injector audible inspection

    179
  • Fuel injector power supply voltage inspection

    180
  • Fuel injector output voltage inspection

    181
  • Injector fuel line inspection

    182
  • Upstream injector resistance inspection

    185
  • Upstream injector output voltage inspection

    187
  • Fuel pump operating voltage inspection

    192
  • Pressure regulator removal

    193
  • Ignition coil (service code)

    195
  • Ecu identification

    196
  • Ecu installation

    197
  • Fuel line

    200
  • Throttle grip and cable

    204
  • Throttle cable lubrication

    205
  • Throttle body assy

    206
  • Throttle body assy installation

    207
  • Throttle body assy assembly

    208
  • Air cleaner

    211
  • Cooling System

    215
  • Coolant draining

    220
  • Coolant filling

    221
  • Cooling system pressure testing

    222
  • Water pump

    223
  • Impeller removal

    224
  • Radiator removal

    227
  • Radiator installation

    228
  • Radiator cap inspection

    229
  • Engine Top End

    231
  • Cylinder head cover

    242
  • Camshaft chain tensioner

    244
  • Camshaft removal

    245
  • Camshaft installation

    246
  • Camshaft chain installation

    249
  • Cam wear inspection

    250
  • Cylinder head

    251
  • Cylinder head installation

    253
  • Valve installation

    256
  • Valve guide installation

    257
  • Valve seat inspection

    258
  • Valve seat repair

    259
  • Cylinder and piston

    263
  • Piston wear inspection

    265
  • Piston ring thickness inspection

    266
  • Throttle body holder

    268
  • Muffler body removal

    269
  • Clutch

    271
  • Clutch lever and cable

    276
  • Clutch cable installation

    277
  • Right engine cover installation

    279
  • Oil seal installation

    280
  • Clutch removal

    281
  • Release shaft installation

    284
  • Engine oil flow chart

    291
  • Engine oil and oil filter

    294
  • Oil pump

    297
  • Oil pressure

    300
  • 8-4 ENGINE REMOVAL/INSTALLATION

    304
  • Crankshaft/Transmission

    311
  • Special tools & sealant

    317
  • Crankcase disassembly

    318
  • Crankcase assembly

    320
  • Crankshaft removal

    325
  • Connecting rod bend inspection

    328
  • Transmission shaft removal

    329
  • Transmission shaft disassembly

    330
  • Shift fork bending inspection

    331
  • Shift fork/gear groove wear inspection

    332
  • Primary gear

    335
  • External shift mechanism

    336
  • External shift mechanism installation

    337
  • External shift mechanism inspection

    338
  • Kick pedal installation

    340
  • Kick shaft installation

    341
  • Wheels/Tires

    343
  • Wheels inspection

    351
  • Axle inspection

    352
  • Tire installation

    354
  • Hub bearing

    356
  • Hub bearing installation

    357
  • Hub bearing inspection

    358
  • Final Drive

    359
  • Special tool

    363
  • Drive chain

    364
  • Engine sprocket removal

    366
  • Rear sprocket installation

    367
  • Brakes

    369
  • Brake lever, brake pedal

    376
  • Brake fluid

    378
  • Brake line bleeding

    379
  • Caliper removal

    381
  • Caliper installation

    382
  • Caliper piston and cylinder damage

    384
  • Brake pad

    385
  • Master cylinder

    387
  • Rear master cylinder installation

    389
  • Master cylinder inspection (visual inspection)

    390
  • Brake disk

    391
  • Brake hose

    392
  • Suspension

    393
  • Front fork

    402
  • Rebound damping adjustment (left fork only)

    403
  • Oil change/oil level adjustment

    404
  • Front fork installation

    405
  • Front fork disassembly

    406
  • Front fork assembly

    407
  • Rear shock absorber

    410
  • Spring preload adjustment

    411
  • Rear shock absorber spring tension inspection

    412
  • Rear shock absorber installation

    413
  • Rear shock absorber assembly

    414
  • Swingarm installation

    416
  • Wear inspection

    417
  • Rocker arm installation

    419
  • Needle bearing inspection

    421
  • Uni-trak maintenance

    422
  • Side covers

    442
  • Electrical System

    445
  • Electrical wiring

    457
  • Flywheel magneto

    458
  • Flywheel installation

    459
  • Stator coil installation

    460
  • Flywheel inspection

    461
  • Charging system

    462
  • Capacitor removal

    463
  • Ignition timing

    464
  • Ignition system

    465
  • Ignition coil inspection

    466
  • Ic igniter inspection

    468
  • Crankshaft sensor inspection

    471
  • Engine stop switch inspection

    472
  • Troubleshooting guide

    496
  • Engine overheating

    497
  • Abnormal drive train noise

    498

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