Kawasaki KLX 250 F 2014, KX250 F 2013 Owner's manual

Quick Reference Guide

GENERAL INFORMATION j

This Quick Reference Guide will assist you in

finding the in

A Table of Contents is included after the

Foreword.

formation you’re looking for.

MAINTENANCE AND ADJUSTMENT j

TROUBLESHOOTING GUIDE j

TUNING j

STORAGE j

IMPORTANT INFORMATION

This vehicle is designed for the operator only, no passengers.

•

This vehicle is a competition model only and was not manufactured for use on public streets, roads or

•

highways. The use of this vehicle should be limited to participation in sanctioned competition events upon a closed

•

course. This vehicle should not be used for general off-road recreational riding.

•

Read owner’s manual.

•

Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance

practices.

DANGER

DANGER indicates a hazardous situation

which, if not avoided, will result in death or

serious injury.

WARNING

WARNING indicates a hazardous situation

which, if not avoided, could result in de ath

or serious injury.

NOTICE

NOTICE is used to

latedtopersonalinjury.

NOTE indicates information that may help or guide

○

youintheopera

address practices not re-

NOTE

tion or service of the vehicle.

IMPORTANT NOTICE

THIS VEHICLE IS A COMP ONLY AND WAS NOT MANUFACTURED FOR, NOR SHOULD IT BE USED ON, PUBLIC STREETS, R OADS, USE OF THIS VEHICLE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON THIS VEHICLE SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL RID ING. READ OWNER ’S MANUA

ETITION MODEL

OR HIGHWAYS. THE

A CLOSED COURSE.

WARNING

THIS VEHIC LE SHOULD NOT BE USED FOR GENERAL OFF-ROAD R ING.

DISCLAIMER OF WARRANTY

This motorcycle is sold AS IS, with all faults, obvious or conce RANTIES, expressed or implied. Including warranties of MERCHANTABILITY or FITNESS FOR PURPOSE.

The purchaser accepts all responsibilities concerning quality, performance, cost of service and/or necess

aled and there are NO WAR-

ary r epairs.

ECREATIONAL RID-

Motorcycle Noise Emi Information

This motorcycle is designed for closed course competition use only. It does not conform to U.S. EPA motorcycle

Off-road motorcycling is a wonderful sport, and we hope you will enjoy it to the fullest. However, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE YOU USE YOUR MOTORCYCLE LEGALLY, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE.

ssion Control

noise standards.

NOTICE

WARNING

The engine exhaust from this product con-

tains chemicals known to the State of Cali-

fornia to cause cancer, birth defects or other

reproductive harm.

FOREWORD

Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-performance machine with superb handling and stability for racing and sporting use .

Your new KX is a highly tuned competition machine for participation in racing events. As with any mechanical device, proper care and maintenance are important for trouble-free operation and top performance. This manual is written to enable you to keep your KX properly tuned and adjusted.

Due to improvements in design and performance made during production, in some cases there may be minor discrepancies between the actual vehicle and the illustrations and text in this manual.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CONTENTS

SPECIFICATIONS............................................ 8

GENERAL INFORMATION.............................. 11

Location of Labels ......................................... 11

Location of Parts ................. .......................... 16

Side Stand ..................................................... 19

Fuel ............................................................... 20

Fuel Requirement:...................................... 21

Kick Pedal ..................................................... 23

Starting the Engine ........................................ 23

Launch Control Mode

DFI Setting Data Selection ............................ 26

Shifting Gears................................................ 27

Stopping the Motor

Stopping the Engine ............... ....................... 28

Break-In......................................................... 29

Daily Pre-Ride Ch

After-Race Ch ecks .......................... .............. 32

MAINTENANCE AND ADJUSTMENT............. 33

Periodic Mainte

Engine Oil ...................................................... 38

Cooling Syste m ............................................. 43

Spark Plug ..................................................... 47

Air Cleaner ......................................... ........... 54

Throttle Cab le ................................................ 60

Throttle Bod y

Clutch ............................................................ 72

Valve Clearance .................. .......................... 79

Assy ........................................

....................................

cycle................................

ecks ..................................

nance Chart ..........................

Exhaust System ............................................ 84

Drive Chain.................................................... 88

Handlebars ........... ......................................... 95

Brakes ............................................. .............. 97

Steering ................ ......................................... 100

Front Suspension .......................................... 103

Rear Suspension (UNI

Wheels .............. ............................................ 159

Hoses Inspect ion ........................................... 161

Tightening Torques

Cleaning Your Motorcycle. ............................. 166

Lubrication ....................................... .............. 168

DFI Self-Diagnosi

TROUBLESHOOTING GUIDE......................... 178

TUNING............................................................ 185

Suspension.................................................... 185

Gearing.......................................................... 191

Special Care According to Track Conditions. 192

OPTIONAL PARTS.......................................... 1 93

PRE-RACE CHECKS AND AFTER-RACE

MAINTENANCE .......................................... .. 194

STORAGE ... ..................................................... 196

Before Storage .................... .......................... 196

After Storage ................................................. 197

ENVIRONMENTA

WIRING DIAGRAM .......................................... 199

of Nuts and Bolts. ...........

s .......................................

L PROTECTION ..................

-TRAK

).....................

153

162

171

198

8 SPECIFICATIONS

SPECIFICATIONS

DIMENSIONS

Overall Length 2 170 mm (85.43 in.)

Overall Width 820 mm (32.3 in.)

Overall Height 1 270 mm (50.00 in.)

Wheelbase

Road Clearance 330 mm (13.0 in.)

Curb Mass 106.0 kg (233.7 lb)

Fuel Tank Capacity 6.1 L (1.6 US gal)

ENGINE

Type

Bore × Stroke 77.0 × 53.6 mm (3.03 × 2.11 in.)

Displacement

Compression Ratio

Fuel System FI (Fuel Injection)

Starting System

Ignition System Digital DC-CDI

Ignition Timing

Lubrication System Forced lubrication (semi-dry sump)

Spark Plug NGK CPR8EB-9

Spark Plug Terminal Solid-post

1 475 mm (58.07 in.)

4-stroke, DOHC, single-cylinder, liquid-cooled

249cm³(15.2cuin.)

13.8:1

Primary kick

4° BT DC @2 000 r/min (rpm)

TRANSMISSION

Transmission Type

Clutch Type

Driving System Chain drive

Gear Ratio:

1st

2nd

3rd

4th

5th

Primary Reduction Ratio

Final Reduction Ratio

Overall Drive Ratio 13.470 @Top gear

Engine Oil:

Type

Viscosity

Capacity 1.0 L (1.1 US qt)

FRAME

Type Tubular, semi-double cradle

Steering Angle 42° to either side

Caster 28.7°

Trail

5-speed, constant m esh, return shift

Wet, multi disc

2.142 (30/14)

1.750 (28/16)

1.444 (26/18)

1.235 (21/17)

1.045 (23/22)

3.350 (67/20)

3.846 (50/13)

API SG, SH , SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

126.4 mm (4.98 in.)

SPECIFICATIONS 9

10 SPECIFICATIONS

Tire Size/Type:

Front

Rear

Rim Size:

Front 21 × 1.60

Rear 19 × 1.85

Suspension:

Front

Rear New U ni-trak

Front Suspension Travel 315 mm (12.4 in.)

Rear Wheel Travel

Front Fork Oil:

Type

Amount (Left Front Fork):

Cylinder Unit 330 mL (11.2 US oz.)

Outer Tube 300 mL (10.1 US oz.)

Amount (Right Front Fork) 223 mL (7.54 US oz.)

BRAKES

Type:

Front

Rear

80/100-21 51M/DUNLOP MX51FA

100/90-19 57M/DUNLOP MX51

Telescopic fork (upside-down)

310 mm (12.2 in.)

Kawasaki Fork Oil SS19

Single disc

swingarm

Specifications are subject to change without notice.

GENERAL INFORMATION

Location of Labels

All warning labels which are on your vehicle are

repeated here. Read lab derstand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may ope fore, it is very important that all warning labe ls be on your vehicle in the locations shown. If any label is missing, damaged, or your Kawasaki dealer and install it in the correct position.

The sample warning labels in this section have

○

part numbers to help the correct replacement.

els on your vehicle and un-

rate your vehicle. There-

worn, get a replacement from

NOTE

you and your dealer obtain

GENERAL INFORMATION 11

1. Brake Fluid (Front)

12 GENERAL INFORMATION

2. Brake Fluid (Rear)

3. Radiator Cap Danger

4. Rear Shock Absorber Warning

5. Noise Emission Control Information

6. Important Information

7. Disclaimer of Warranty

GENERAL INFORMATION 13

14 GENERAL INFORMATION

GENERAL INFORMATION 15

16 GENERAL INFORMATION

Location of Parts

1. Clutch Lever

2. Engine Stop Button

3. Launch Control Mode Button

4. Orange Launch Control Mode/FI Warning Indicator Light

5. Fuel Tank Cap

6. Front Brake Fluid Reservoir

7. Front Brake Lever

8. Throttle Grip

GENERAL INFORMATION 17

1. Front For

2. Radiator

3. Fuel Tank

4. Throttl

5. Downstream Injector

e Body Assy

6. Upstream

7. Seat

8. Air Cleaner Element

9. Brake Di

10. Brake Caliper

Injector

11. S hi ft Ped

12. Rear Shock Absorber

13. Swingarm

14. Drive Ch

15. Chain Guide

ain

18 GENERAL INFORMATION

1. Muffler

2. Rear Brake Fluid Reservoir

3. Rear Shock Absorber Gas Reservoir

4. Kick Ped

5. DFI Setting Data Selection Connector

6. Uni-Trak

Tie-Rod and Ro cker Arm

7. Oil Level Inspection Window

8. Rear Brake Pedal

9. Exhaust

Pipe

Side Stand

To install the side st

rear axle as shown in the figure.

A. Side Stand B. Rear Axle

and, insert its flat end into the

WARNING

Riding with the s resulting in injury. Do not start the engine or attempt to ride th e motorcycle when the side stand is instal

idestandcancauseacrash

led.

GENERAL INFORMATION 19

NOTE

Support the motorcycle with a suitable stand to

○

perform maintenance or adjustment procedures.

20 GENERAL INFORMATION

Fuel

This Kawasaki KX has a

quires a gasoline.

The capacity of the fuel tank is 6.1 L (1.6 US gal). To open the fuel tank c hose from the hole in the steering stem, and turn the tank cap counterclockwise.

A. Fuel Tank Cap

B. Breather Hose

4-stroke engine that re-

ap, disconnect the breather

Avoid filling the tan

k in the rain or where heavy dust

is blowing so that the fuel does not get contaminated.

A. Tank Cap B. Fuel Tank C. Top Level D. Filler Neck

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the fuel tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.

Fuel Requirement:

Fuel Type

Use clean, fresh unleaded gasoline with a minimum Antiknock I posted on service station pumps in the U.S.A. The octane rating of a gasoline is a measure of its resistance to de Index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON) as shown in t he t

Octane Rating Meth od

Antiknock Index

ndex of 90. The Antiknock Index is

tonation or “knocking”. The Antiknock

able below.

Minimum

Rating

(RON + MON)

GENERAL INFORMATION 21

NOTICE

If engine “knocking” or “pinging” occurs, use a different brand of gasoline of a higher octane rating. If this condition is allowed to continue it can lead to severe engine damage. Gasoline quality is quality or not meeting standard industry specifications may result in unsatisfactory performance. Oper from the use of poor quality or nonrecommended fuel may not be covered under your warranty.

Fuels Containing Oxygenates

Gasoline frequently contains oxygenates (alcohols and ethers) especially in areas of the U.S. and Canada which are required to sell such reformulated fuels as part of a strategy to reduce exhaust emissions.

The types and volume of fuel oxygenates approved for use in unleaded gasoline by the U.S. Environmental Protection Agency include a broad range of alcohols and ethers, but only two components have seen any significant level of commercial use.

Gasoline/Alcohol Blends - Gasoline containing up to 10% ethanol (alcohol produced from agricultural products such as corn), also known as “gasohol” is approved for use.

important. Fuels of low

ating problems that result

22 GENERAL INFORMATION

NOTICE

Avoid using blends of unleaded gasoline and methanol (wood alcohol) whenever possible, and never use “gasoh than 5% methanol. Fuel system damage and performance problems m ay result.

Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTB E). You may use gasoline contain

Other oxygenates

○

gasoline include TAME (up to 16.7%) and ETBE (up to 17.2%). Fuel containing these oxygenates canalsobeusedi

ingupto15%MTBE.

ol” containing more

NOTE

approved for use in unleaded

n your Kawasaki.

NOTICE

Never use gasoline with an octane rating lower than the minimum specified by Kawasaki. Never use “gasohol” with more than 10% ethanol, or more than 5% methanol. Gasoline containing met blended with cosolvents and corrosion inhibitors. Certain ingredien paint fading or damage. Be extra careful not to spill gasoline or gasoline oxygenate blends during ref When not operating your Kawasaki for 30 to 60 days, mix a fuel stabilizer (such as STA-BIL) with th Fuel stabilizer additives inhibit oxidation of the fuel which minimizes gummy deposits. Never store this the fuel system. Before storage it is recommended that you drain all fuel from the fuel system. See the ual.

hanol must also be

ts of gasoline may cause

ueling.

e gasoline in the fuel tank.

product with “gasohol” in

Storage section in this man-

GENERAL INFORMATION 23

Kick Pedal

This motorcycle is eq starting system. When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear.

A. Kick Pedal

uippedwithaprimarykick

Starting the Engine

Shift the transmissi

•

on into neutral.

WARNING

Ridingwiththesidestandcancauseacrash resulting in injury. Do not start the engine or attempt to ride the motorcycle when the side stand is installed.

NOTICE

This motorcycle is designed for competition use only. Therefor incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow throu coolant loss and engine overheating resulting in possible engine damage. Any riding conditions that will further reduce idling time before coolant loss occurs. These conditions include high ambient temper rain, or other conditions causing high engine loads at low speeds. Furthermore, warming the engine up e or leaving idling with the hot engine temperature after operation results in the engine overheating

,too.

e, the r adiator does not

gh the radiator can cause

increase engine temperature

ature, sandy or muddy ter-

xcessively before operation,

24 GENERAL INFORMATION

When engine is cold -

Pull out the idle adjusting screw/choke knob.

•

A. Idle Adjusting Screw/Choke Knob

Find the kick pedal position around the top so that

•

the resistance to depress the kick pedal is fully felt by pushing down the kick pedal slowly. Kick the engi

•

When the clut

○

be started with the transmission in any gear.

Even after t

•

back immediately the idle adjusting screw/choke knob until the engine is thoroughly warmed up.

ne over, leaving the throttle closed.

NOTE

ch lever is pulled, the motorcycle can

he engine has started, do not push

When engine is alread

Kick the engine over, leaving the thro ttle closed

•

without using the idle adjusting screw/choke knob.

If the engine fails starting, open the throttle fully

○

and depress the kick pedal slowly about 4 times to clear too rich fuel mixtures in the engine. Then, kick the engine over, leaving the throttle closed.

y warm or restarts -

NOTE

∼

Launch Control Mode

When shifting into 3r

•

automatically.

GENERAL INFORMATION 25

d, the system is deactivated

The launch control mo nition timing to help riders get better starts on slippery terrain.

The system’s effecti skill, technique and terrain conditions.

decanbeusedtoadjustig-

veness is dependent on rider

Launch Control Mode Setting

The launch control mode can be set when the en-

•

gine is running and in neutral, 1st or 2nd gear. When activated, it only functions in 1st and 2nd gear. When pushing the launch control mode button for

•

over two seconds, indicator light w ill blink to indicate the system is operating.

the orange launch control mode

A. Launch Control Mode Button B. Orange Launch Control Mode/FI Warning

Indicator Light

26 GENERAL INFORMATION

DFI Setting Data Selection

Three DFI settings ar track conditions. They are easily activated by changing the wiring connector on the side of the frame when the engine is sto

Track Condition Connector Color

Soft

Standard Green

Hard Black

Change the connector on the right front of the

•

e to suit the track condition with the engine

fram stopped.

e available to suit various

pped.

White

NOTE

If the connector is changed while the engine is

○

running, the DFI setting does not change. The ECU is set to the standard track condition

○

when operated without a connector. However, always have one of the three connectors attached when riding to prevent dust and mud from accumulating in the connector harness. The KX FI calibration kit (Part No. 99999-0394)

○

can be used for changing the DFI setting.

A. Connector

Shifting Gears

GENERAL INFORMATION 27

This motorcycle is eq shift” transmission. The neutral is located halfway between 1st and 2nd gear. “Return shift” means that when shifting up engaged before the next higher or lower gear may be selected.

To engage first gea

•

intheclutchleverandpushdownontheshift pedal, gently release the clutch lever, then release the shift pedal. To shift up to the next gear, pull in the clutch lever,

•

lift the shift pedal with your toes, gently release the clutch lever, an To shift down to the next gear, pull in the clutch

•

lever, push the shift pedal down as far as it will go, gently release t shift pedal.

uipped with a 5-speed “return

or down, each gear must be

r from the neutral position, pull

d then release the shift pedal.

he clutch lever, then release the

NOTICE

When changing gears, press firmly on the

shift pedal to ensure proper shifting. Care-

less, incomplete shifting can cause the

transmission to jump out of gear and lead to

engine damage.

A. Shift Pedal

28 GENERAL INFORMATION

Stopping the Motorcycle

For maximum decelera apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front o geous in certain circu ms ta nc es . Shift down progressively to ensure good engine response at all speeds.

tion, close the throttle and

r rear brake may be advanta-

Stopping the Engine

Shift the transmissi

•

Close the throttle completely and push the engine

•

stop button.

A. Engine Stop Button

on into the neutral position.

Break-In

A brief break-in proc obtain the proper operating clearances in the engin e and transmission, which are necessary for performance and reliabilit

edure must be carried out to

NOTICE

For the first hour or 20 km (12 mile) of op-

eration, run the engine at low and moderate

engine speeds. See details below.

Break in the engine as follows.

1. Start the engine and let it idle until it is thor-

oughly warmed up.

2. Ride the motorcycle for about 20 minutes within

1/2 throttle opening.

3. Stop and let the engine cool completely. Be

sure to check the tightness of nuts a nd bolts, oil leakage, coolant leakage and any irregularities.

4. Start the engine and ride the motorcycle for

about 40 minutes within 3/4 throttle opening.

GENERAL INFORMATION 29

5. Stop and let the engin sure to fully check the tightness of nuts and bolts, oil leakage, and any irregularities, especially, each cable e slack and spoke tightness.

6. Change the engine oil, oil filter and front fork/rear shock ab

7. After the break-in procedure has been properly carried out, the motorcycle is ready for regular operation. Using techniques and avoiding recklessly high engine speeds will keep the engine trouble-free.

e cool completely. Be

longation, brake play, chain

sorber oil to the new one.

the proper riding skills an d

NOTICE

When any following parts have been replaced, the same break-in procedure as the new motorcycle must be carried out for one hour or 20 km (12 mile): Cylinder, Piston, Piston pin, Piston ring, Valve, Valve lifter, Camshaft, Crankshaft, Mission gear, etc.

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