Kawasaki KX250F Service Manual

KX250F

Motorcycle

Service Manual

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

Crankshaft/Transmission 9 j

This quick reference guide will assist you in locating a desired topic or procedure.

•Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.

•Refer to the sectional table of contents for the exact pages to locate the specific topic required.

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

KX250F

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

LIST OF ABBREVIATIONS

A ampere(s) KDS Kawasaki Diagnostic System

ABDC after bottom dead center km/h

Ah ampere hour lb

ATDC after top dead center LED Light Emitting Diode

BBDC before bottom dead center m meter(s)

BDC bottom dead center min minute(s)

BTDC before top dead center mph miles per hour

°C degree(s) Celsius N newton(s)

cmHg centimeters of mercury oz ounce(s)

cu in cubic inch(s) Pa pascal(s)

DC direct current PS horsepower

DFI Digital Fuel Inject

ECU Electronic Control Unit

°F degree(s) Fahren

ft foot, feet s second(s)

ggram(s) TDC top dead center

gal gallon(s) TIR total indicator reading

h hour(s) Vvolt(s)

HP horsepower(s) W watt(s)

in. inch(s) Ω ohm(s)

alternating current

ion

farad(s)

heit

psi pound(s) per square inch

r revolution

rpm

kilometers per hour

liter(s)

pound(s)

quart(s)

revolution(s) pe

rminute

COUNTRY AND AREA CODES

AU Australia EUR Europe

BR Brazil TH Thailand

CA Canada US United States

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

To get the longest life out of your vehicle:

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want stick coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Stick Coil section.

Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

This manual contains four more symbols which will help you distinguish different types of information.

NOTE

NOTE indicates information that may help

○

or guide you in the operation or service of

the vehicle.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease o r a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Unit Conversion Table ............................................................................................................ 1-11

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high flash-point solvent when cleaning parts. High flash-point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Before Servicing

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

GENERAL INFORMATION 1-3

Replacement Parts

Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Before Servicing

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

GENERAL INFORMATION 1-5

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

1-6 GENERAL INFORMATION

Before Servicing

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Leads

A two-color lead is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for a n accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

Model Identification

KX250ZD Left Side View

GENERAL INFORMATION 1-7

KX250ZD Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

General Specifications

Items KX250ZD ∼ ZE

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 1 475 mm (58.07 in.)

Road Clearance 330 mm (13.0 in.)

Seat Height 945 mm (37.2 in.)

Curb Mass: 106.2 kg (234.2 lb)

(US, CA) 106.0 kg (233.7 lb)

Front:

Rear:

Fuel Tank Capacity 6.1 L (1.6 US gal)

Engine

Type 4-stroke, single cylinder, DOHC 4 valve

Cooling System

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

Displacement 249 cm³ (15.2 cu in.)

Compression Ratio 13.8:1

Fuel System FI (Fuel Injection), KEIHIN 43

Fuel Type:

Minimum Octane Rating:

Research Octane Number (RON) (AU, EUR, TH) 95

Antiknock Index (RON + MON)/2 (US, CA, BR) 90

Starting System

Ignition System Digital DC-CDI

Timing Advance Electronically advanced

Ignition Timing

Spark Plug:

Standard: NGK CPR8EB-9

Terminal Solid post

Option: NGK CPR9EB-9

Terminal Solid post

Valve Timing:

Intake:

Open BTDC 36°

Close ABDC 76°

Duration 292°

Exhaust:

Open BBDC 69°

Close ATDC 49°

Duration 298°

Lubrication System Forced lubrication (semi-dry sump)

51.7 kg (114.0 lb)

54.5 kg (120.2 lb) (US, CA) 54.3 kg (119.7 lb)

Liquid-cooled

Primary kick

BTDC 4° at 2 000 r/min (rpm)

GENERAL INFORMATION 1-9

General Specifications

Items KX250ZD ∼ ZE

Engine Oil:

Type

Viscosity

Capacity 1.0 L (1.1 US qt)

Drive Train

Primary Reduction System:

Type

Reduction Ratio 3.350 (67/20)

Clutch Type Wet multi disc, Manual

Transmission:

Type 5-speed, constant mesh, return shift

Gear Ratios:

1st 2.142 (30/14)

2nd 1.750 (28/16)

3rd

4th

5th 1.045 (23/22)

Final Drive System:

Type Chain drive

Reduction Ratio 3.846 (50/13)

Overall Drive Ratio

Frame

Type Tubular, semi-double cradle

Steering Angle 42° to either side

Caster (Rake Angle) 28.7°

Trail 126.4 mm (4.976 in.)

Front Wheel:

Tire Size 80/100-21 51M

Tire Make/Type DUNLOP MX51FA, Tube type

Rim Size

Rear Wheel:

Tire Size 100/90-19 57M

Tire Make/Type DUNLOP MX51, Tube type

Rim Size

Front Suspension:

Type Telescopic fork (upside down)

Wheel Travel 315 mm (12.4 in.)

Rear Suspension:

Type

Wheel Travel

Brake Type:

Front and Rear

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

SAE 10W-40

Gear

1.444 (26/18)

1.235 (21/17)

13.470 at Top gear

21 × 1.60

19 × 1.85

Swingarm (New Uni-trak)

310 mm (12.2 in.)

Single disc

1-10 GENERAL INFORMATION

General Specifications

Items KX250ZD ∼ ZE

Effective Disc Diameter:

Front 225 mm (8.86 in.)

Rear 215 mm (8.46 in.)

Specifications are subject to change without notice, and may not apply to every country.

Unit Conversion Table

GENERAL INFORMATION 1-11

Prefixes for Units:

Prefix Symbol Power

mega M × 1 000 000

kilo k ×1000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units of Mass:

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US)

L × 0.2200 = gal (IMP)

L × 1.057 =

L × 0.8799 =

L × 2.113 = pint (US)

L × 1.816 = pint (IMP)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (IMP)

mL × 0.06102 = cu in.

qt (US)

qt (IMP)

Units o f Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in.

Units o f Torque:

N·m × 0.1020 = kgf·m

N·m × 0.7376 = ft·lb

N·m × 8.851 = in·lb

kgf·m × 9.807 = N·m

kgf·m × 7.233 = ft·lb

kgf·m × 86.80 = in·lb

Units of Pressure:

kPa × 0.01020 = kgf/cm²

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cmHg×1.333=kPa

Units of Speed:

km/h

× 0.6214 = mph

Units o f Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature:

Units of Power:

kW ×1.360=PS

kW ×1.341=HP

PS × 0.9863 = HP

× 0.7355 = kW

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-5

Specifications ......................................................................................................................... 2-9

Special Tools .......................................................................................................................... 2-12

Periodic Maintenance Procedures.......................................................................................... 2-14

Fuel System (DFI)................................................................................................................ 2-14

Fuel Hose and Connections Inspection ............................................................................ 2-14

Throttle Grip (Throttle Cable) Free Play Inspection .......................................................... 2-14

Throttle Grip (Throttle Cable) Free Play Adjustment......................................................... 2-14

Throttle B ody Cleaning ..................................................................................................... 2-15

Fuel Hose Replacement ................................................................................................... 2-15

Idle Speed Inspection ....................................................................................................... 2-18

Idle Speed Adjustment...................................................................................................... 2-19

Air Cleaner Element Cleaning and Inspection .................................................................. 2-19

Fuel Tank Cleaning ........................................................................................................... 2-21

Cooling System.................................................................................................................... 2-21

Coolant Level Inspection................................................................................................... 2-22

Coolant Deterioration Inspection....................................................................................... 2-23

Water Hoses and Connections Inspection ........................................................................ 2-23

Engine Top End ................................................................................................................... 2-23

Valve Clearance Inspection .............................................................................................. 2-23

Valve Clearance Adjustment............................................................................................. 2-24

Cylinder Head Warp Inspection ........................................................................................ 2-26

Cylinder Wear Inspection.................................................................................................. 2-26

Piston/Cylinder Clearance Inspection ............................................................................... 2-27

Piston, Piston Ring and Piston Pin Replacement ............................................................. 2-27

Exhaust S ystem Inspection............................................................................................... 2-27

Silencer Wool Replacement.............................................................................................. 2-28

Clutch................................................................................................................................... 2-29

Clutch Operation Inspection.............................................................................................. 2-29

Clutch Plates Inspection ................................................................................................... 2-29

Engine Lubrication System .................................................................................................. 2-30

Engine Oil Change............................................................................................................ 2-30

Oil Filter Change ............................................................................................................... 2-31

Breather Hose Inspection ................................................................................................. 2-32

Crankshaft/Transmission ..................................................................................................... 2-33

Crankshaft Inspection ....................................................................................................... 2-33

Wheels/Tires........................................................................................................................ 2-33

Air Pressure Inspection/Adjustment.................................................................................. 2-33

Tires Inspection.................................................................................................................2-34

Spoke Tightness Inspection.............................................................................................. 2-34

Rim Runout Inspection...................................................................................................... 2-34

Wheel Bearing Inspection ................................................................................................. 2-35

Final Drive............................................................................................................................ 2-35

Drive Chain Wear Inspection ............................................................................................ 2-35

Drive Chain Slack Inspection ............................................................................................ 2-36

Drive Chain Slack Adjustment .......................................................................................... 2-37

Drive Chain Lubrication..................................................................................................... 2-38

Sprocket Wear Inspection................................................................................................. 2-38

Rear Sprocket Warp (Runout) Inspection ......................................................................... 2-38

2-2 PERIODIC MAINTENANCE

Brakes.................................................................................................................................. 2-39

Brake Lever and Pedal Adjustment .................................................................................. 2-39

Brake Fluid Level Inspection ............................................................................................. 2-40

Brake Fluid Change .......................................................................................................... 2-41

Brake Pad Wear Inspection .............................................................................................. 2-43

Brake Master Cylinder Rubber Parts Replacement .......................................................... 2-43

Caliper Rubber Parts Replacement .................................................................................. 2-45

Brake Hoses and Connections Inspection ........................................................................ 2-48

Brake Hose Replacement ................................................................................................. 2-48

Suspension.......................................................................................................................... 2-50

Front Fork Inspection ........................................................................................................ 2-50

Front Fork Oil Change ...................................................................................................... 2-50

Rear Shock Absorber Oil Change..................................................................................... 2-70

Swingarm and Uni-Trak Linkage Inspection ..................................................................... 2-78

Swingarm and Uni-Trak Linkage Pivot Lubrication ........................................................... 2-78

Steering ............................................................................................................................... 2-79

Steering Inspection ........................................................................................................... 2-79

Steering Adjustment ......................................................................................................... 2-79

Steering Stem Bearing Lubrication ................................................................................... 2-80

Frame .................................................................................................................................. 2-81

Frame Inspection .............................................................................................................. 2-81

Electrical System ................................................................................................................. 2-81

Spark Plug Cleaning and Inspection ................................................................................. 2-81

Spark Plug Replacement .................................................................................................. 2-81

General Lubrication and Cable Inspection........................................................................... 2-82

Lubrication ........................................................................................................................ 2-82

Cable Inspection ............................................................................................................... 2-83

Nut, Bolt, and Fastener Tightness Inspection...................................................................... 2-83

Tightness Inspection ......................................................................................................... 2-83

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The maintenance must be done in accordance with this chart to keep the motorcycle in good running

condition.

FREQUENCY

OPERATION

Spark plug - clean and inspect †

Spark plug - replace

Clutch - inspect

Clutch plates - inspect †

Throttle cable - inspect and adjust

Air cleaner element - clean

Air cleaner element - replace

Throttle body assy - inspect and adjust

Engine oil - change

Piston and piston ring - replace

Cylinder head, cylinder - inspect

Piston pin - replace

Valve clearance - inspect †

Oil filter - replace

Exhaust system - inspect †

Silencer wool - change

Kick pedal and shift pedal - clean

Engine sprocket - inspect †

Coolant level - inspect

Water hoses and connections - inspect †

Crankshaft - inspect

Breather hose - inspect

Brake - adjust †

Brake pad wear - inspect †

Brake fluid level - inspect †

Brake fluid - change Every 2 years 2-41

Brake master cylinder cup and dust cover - replace Every 2 years 2-43

Brake caliper fluid seal and dust seal - replace

H A

Brake hoses - replace Every 4 years 2-48

Brake hoses, connections - inspect †

Spoke tightness and rim runout - inspect †

Wheel bearing - inspect †

Frame - inspect

Drive chain wear - inspect †

Drive chain - inspect and adjust

Drive chain - lubricate

Each

race

or 2.5

hours

•

Every

3 races

or 7.5

hours

Every 6

races or 15 hours

Every 12

races or

30 hours

Page

•

If damaged

•

Every 2 years 2-45

See

2-81

2-29

2-14

2-19

2-15

2-30

2-27

2-26

2-27

2-23

2-31

2-27

2-28

–

2-38

2-22

2-23

2-33

2-32

2-39

2-43

2-40

2-48

2-34

2-35

2-81

2-35

2-36

2-38

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

OPERATION

Wheels/tires - inspect

Rear sprocket - inspect †

Front fork - clean and inspect

Front fork oil - change

Rear shock absorber oil

Cable - inspect

Fuel hose - replace Every 5 years 2-15

Fuel hose, connections - inspect †

S S

Fuel system - clean

Steering play - inspect †

Steering stem bearing - lubricate

Swingarm and Uni-Trak linkage pivots - lubricate

Swingarm and Uni-Trak linkage pivots - inspect †

Nuts, bolts, fasteners - inspect †

General lubrication - perform

†: Replace, add, adjust, clean or torque if necessary.

- change

Each

race

or 2.5

hours

•

Every

3 races

or 7.5

hours

•

Every 6

races or 15 hours

•

Every 12

races or

30 hours

See

Page

2-34

2-38

2-50

2-70

2-83

2-14

2-21

2-79

2-80

2-78

2-83

2-82

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or silicone grease etc.

When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten to specified torque. Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

L: Apply a non-permanent locking agent.

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

T: First, tighten the stem nut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and retighten

it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.

2T: Apply 2-stroke oil.

Fastener

Fuel System (DFI)

Throttle Pulley Cover Bolts 3.4 0.35 30 in·lb

Throttle Cable Bolts 3.0 0.31 27 in·lb

Air Cleaner Duct Clamp Bolt

Throttle Case M ounting Screws

Delivery Joint Bolt 3.5 0.36 31 in·lb L

Water Temperature Sensor

Gear Position Switch Screws

Cooling System

Water Hose Clamp Screws 3.0 0.31 27 in·lb

Water Pipe Bolt 9.8 1.0 87 in·lb

Water Pump Cover Bolts (L = 55 mm) 9.8 1.0 87 in·lb L

Water Pump Impeller Bolt 7.0 0.71 62 in·lb

Water Pump Cover Bolts (L = 30, 65 mm)

Coolant Drain Bolt 7.0 0.71 62 in·lb

Engine Top End

Cylinder Head Cover Bolts

Camshaft Cap Bolts 9.8 1.0 87 in·lb MO, S

Plug 20 2.0 15 L

Cylinder Head Bolts (M10)

Auto-Decompressor Bolt 12 1.2 106 in·lb

Cylinder Head Bolts (M6)

Cylinder Bolt

Throttle Body Assy Clamp Screw 2.0 0.20 18 in·lb

Throttle B ody Assy Holder Clamp Screw 2.0 0.20 18 in·lb

Lower Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb

Rear Camshaft Chain Guide Bolt 15 1.5 11

N·m kgf·m ft·lb

2.0 0.20 18 in·lb

3.8 0.39 34 in·lb

12 1.2 106 in·lb

2.9 0.30 26 in·lb L

9.8 1.0 87 in·lb

44 4.5 32

12 1.2 106 in·lb

Torque

Remarks

MO,R,S

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Camshaft Chain Tensioner Cap Bolt 20 2.0 15

Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb

Clutch

Right Engine Cover Bolts 9.8 1.0 87 in·lb

Clutch Cover Bolts 9.8 1.0 87 in·lb

Oil Filler Plug 3.5 0.36 31 in·lb

Clutch Hub Nut 98 10.0 72 R

Clutch Spring Bolts 9.0 0.92 80 in·lb

Engine Lubrication System

Oil Filter Cap Bolts 9.8 1.0 87 in·lb

Piston Oil Nozzle 2.9 0.30 26 in·lb

Breather Fitting 15 1.5 11

Oil Pump Idle Gear Shaft Screws 5.9 0.60 52 in·lb L

Oil Pump Mounting Bolts 7.0 0.71 62 in·lb L

Engine Oil Drain Bolt 20 2.0 15

Engine Removal/Installation

Upper Engine Mounting Bolts 49 5.0 36 S

Upper Engine Bracket Bolts 29 3.0 21

Middle Engine B

Middle Engine Mounting Nut 49 5.0 36 R, S

Lower Engine Mounting Nut 49 5.0 36 R, S

Swingarm Pivot Shaft Nut 98 10.0 72 R, S

Crankshaft/Transmission

Primary Gear Nut

Reed Valve Screws 7.0 0.71 62 in·lb

Crankcase Bearing Retainer Screws 15 1.5 11 L

Piston Oil Nozzle 2.9 0.30 26 in·lb

Crankcase Bolts (L = 50 mm) 9.8 1.0 87 in·lb S

Crankcase Bolt (L = 65 mm) 9.8 1.0 87 in·lb S

Crankcase Bolts (L = 70 mm)

Crankcase Bolts (L = 60 mm) 9.8 1.0 87 in·lb S

Kick Ratchet Guide Bolt

Kick Pedal Bolt 25 2.5 18 L

Shift Drum Cam Bolt 24 2.4 18 L

Gear Positioning Lever Nut 8.8 0.90 78 in·lb

Ratchet Plate Bolt 9.8 1.0 87 in·lb L, S

Ratchet Plate Screw 15 1.5 11 L, S

Shift Pedal Bolt 9.8 1.0 87 in·lb

Wheels/Tires

Spoke Nipples

Front Axle Nut 78 8.0 58

Front Axle Clamp Bolts 20 2.0 15 AL, S

racket Nuts

N·m kgf·m ft·lb

29 3.0 21 R, S

98 10.0 72 Lh, R

9.8 1.0 87 in·lb

8.8 0.90 78 in·lb

Not less than 2.2

Torque

Not less than

0.22

Remarks

Not less than

19 in·lb

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Rear Axle Nut 108 11.0 79.7

Final Drive

Rear Sprocket Nuts 34 3.5 25 R

Engine Sprocket Nut (KX250ZE) 78 8.0 57

Brakes

Brake Hose Banjo Bolts 25 2.5 18

Front Brake Reservoir Cap Screws

Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S

Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si

Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb

Front Brake Disc Mounting Bolts 9.8 1.0 87 in·lb L

Front Brake Pad Pin 17 1.7 13

Caliper Bleed Valves 7.8 0.80 69 in·lb

Front Caliper Mounting Bolts 25 2.5 18

Rear Brake Reservoir Cap Bolts

Rear Master Cylinder Mounting Bolts

Rear Master Cylinder Push Rod Locknut 17 1.7 13

Brake Pedal Bolt 25 2.5 18 G, L

Rear Caliper Holder Shaft 27 2.8 20 Si

Rear Brake Pad Pin 17 1.7 13

Rear Brake Pad Pin Plug 2.4 0.24 21 in·lb

Rear Brake Disc Mounting Bolts 23 2.3 17 L

Suspension

Air Pressure Relief Screws

Left Front Fork Base Valve Assembly

Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L

Front Fork Clamp Bolts (Lower) 22 2.2 16 AL

Right Front Fork Spring Adjuster Unit 34 3.5 25

Left Front Fork Cylinder Unit 34 3.5 25

Left Front Fork Adjuster Assembly Locknut

Left Front Fork Adjuster Assembly

Right F ront Fork Spring Preload Adjuster 30 3.1 22

Right Front Fork Bottom Plug Locknut 22 2.2 16

Right Front Fork Bottom Plug 69 7.0 51 L

Rear Shock Absorber Mounting Nut (Upper)

Rear Shock Absorber Mounting Nut (Lower)

Tie-Rod Mounting Nuts 59 6.0 44 R

Swingarm Pivot Shaft Nut

Rocker Arm Pivot Nut 59 6.0 44 R

Gas Reservoir Damping Adjuster Assembly

Rear Shock Absorber Spring Locknut 45 4.6 33

N·m

1.5 0.15 13 in·lb

9.8 1.0 87 in·lb

1.3 0.13 12 in·lb

30 3.1 22

22 2.2 16

69 7.0 51 L

39 4.0 29 R

34 3.5 25 R

98 10.0 72 R

29.5 3.01 21.8

Torque

kgf·m ft·lb

Remarks

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Piston Rod Locknut 37 3.8 27 R

Steering

Handlebar Clamp Bolts 25 2.5 18 AL, 2T

Steering Stem Head Nut 98 10.0 72

Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L

Steering Stem Nut

Handlebar Holder Nuts 34 3.5 25 R

Front Fork Clamp Bolts (Lower) 22 2.2 16 AL

Brake Hose Clamp Bolt

Frame

Footpeg Bracket Bolts (Upper) 54 5.5 40 L

Rear Frame Mounting Bolts 34 3.5 25

Electrical System

Regulator/Rectifier Nuts 10 1.02 89 in·lb R

Spark Plug

Flywheel Nut Cap 3.5 0.36 31 in·lb

Magneto Cover Bolts 9.8 1.0 87 in·lb

Timing Inspection Cap 3.5 0.36 31 in·lb

Flywheel Nut 78.5 8.00 57.9

Stator Coil Bolts 9.8 1.0 87 in·lb L

Crankshaft Sensor Bolts 7.0 0.71 62 in·lb L

Gear Position Switch Screws 2.9 0.30 26 in·lb L

N·m kgf·m ft·lb

4.9 0.50 43 in·lb T

3.0 0.31 27 in·lb

13 1.3 115 in·lb

Torque

Remarks

Basic Torque for General Fasteners

Threads Diameter

(mm)

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb

8 14 ∼ 19 1.4 ∼ 1.9 10 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72 16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115 18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165 20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240

N·m kgf·m ft·lb

Torque

PERIODIC MAINTENANCE 2-9

Specifications

Item Standard Service Limit

Fuel System (DFI)

Throttle Grip Free Play 2 ∼ 3mm(0.08∼ 0.12 in.) –––

Idle Speed 2 050 ±50 r/min (rpm) –––

Air Cleaner Element Oil High quality foam air filter oil

Cooling System

Coolant:

Type (Recommended) Permanent type antifreeze –––

Color Green –––

Mixed Ratio Soft water 50%, coolant 50% –––

Freezing Point

Tot a l A mo un t

Engine Top End

Valve Clearance:

Exhaust

Intake 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) –––

Cylinder Head Warp ––– 0.05 mm

Cylinder Inside Diameter (see text) 77.000 ∼ 77.012 mm 77.10 mm

Piston/Cylinder Clearance

Clutch

Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) ––– Friction Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.5 mm (0.10 in.)

Friction Plate Warp

Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)

Engine Lubrication System

Engine Oil:

Type Castrol “POWER1 Racing 4T” 5W-40 or

Viscosity

Capacity 0.75 L (0.79 US qt) (when filter is not

Crankshaft/Transmission

Connecting Rod Big End Side Clearance

–35°C (–31°F)

1.2 L (1.3 US qt)

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

(3.0315 ∼ 3.0320 in.) (3.035 in.)

0.041 ∼ 0.068 mm ––– (0.0016 ∼ 0.0027 in.)

0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)

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

SAE 10W-30, 10W-40, or 10W-50

removed)

0.80 L (0.85 US qt) (when filter is removed)

1.00 L (1.06 US qt) (when engine is completely dry)

0.25 ∼ 0.35 mm 0.6 mm (0.0098 ∼ 0.0138 in.) (0.02 in.)

–––

(0.002 in.)

–––

2-10 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Wheels/Tires

Rim Runout (with tire installed):

Axial

Radial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm

Tires Air Pressure (Front/Rear) 100 kPa (1.00 kgf/cm², 14 psi)

Standard Tire:

Front:

Size 80/100-21 51M

Make DUNLOP –––

Type MX51FA, Tube –––

Rear:

Size 100/90-19 57M –––

Make DUNLOP –––

Type MX51, Tube –––

Final Drive

DriveChainSlack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) ––– Drive Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

Rear Sprocket Warp (Runout) TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm

Brakes

Brake Lever Free Play Adjustable (to suit rider) –––

Brake Fluid Type:

Front DOT3 or DOT4 –––

Rear DOT3 or DOT4 –––

Brake Pad Lining Thickness:

Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)

Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.)

Suspension

Front Fork

KX250ZD

Suspension Oil Kawasaki SS-19 or equivalent –––

Amount (Left Front Fork):

Cylinder Unit 330 mL (11.16 US oz.) –––

Cylinder Unit Oil Level 115 ∼ 123 mm (4.53 ∼ 4.84 in.) –––

Outer Tube 320 ±2.5 mL (10.82 ±0.085 US oz.)

Amount (Right Front Fork) 235 ±2.5 mL (7.95 ±0.085 US oz.) (Adjustable Range)

KX250ZE

Suspension Oil Kawasaki SS-19 or equivalent

TIR 1.0 mm (0.04 in.) or less

(EUR, BR) 300 ±2.5 mL (10.14 ±0.085 US oz.)

TIR 2.0 mm

(0.08 in.)

–––

(0.020 in.)

(Adjustable Range)

300 ∼ 340 mL

(10.14 ∼ 11.50

US oz.)

230 ∼ 378 mL (7.78 ∼ 12.78

US oz.)

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