Crossfire xz250r V4 Owner's Manual
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Crossfire xz250r V4 Owner's Manual

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  • Page 2 This manual contains the latest product information available before printing. Crossfire Motorcycle Pty Ltd. reserves the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission.
  • Page 3 It shall be acceptable to stop manufacturing a certain model without prior notice. In the event of such modifications, please ask your local Crossfire dealer for information...

  • Page 4: Important Warranty Information

    Crossfires obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective parts and Crossfire does not assume or authorize anyone to assume for them any other obligation. No service center and/or dealer is authorized to modify this warranty.

  • Page 5: Table Of Contents

    CONTENTS IMPORTANT WARRANTY INFORMATION SUSPENSION SYSTEM 39 - 42 INTRODUCTION FRONT SUSPENSION INSPECTION IMPORTANT SAFETY INFORMATION 07, 08 FRONT SUSPENSION ADJUSTMENT SAFETY INFORMATION FOR PARENTS REAR SUSPENSION INSPECTION SAFETY LABEL INFORMATION REAR SUSPENSION ADJUSTMENT 41, 42 11 - 12 COMPONENT LOCATIONS 43, 44 RIMS, TIRES &...

  • Page 6: Introduction

    INTRODUCTION Congratulations on choosing your Crossfire off-road motorcycle. Your Crossfire dirt bike was designed as a recreational motorcycle for off-road use only by a single rider only. This motorcycle is ideal for riders with basic experience. Before riding, take plenty of time to get acquainted with your motorcycle and how it works.

  • Page 7: Important Safety Information

    Your personal safety, and the safety of those around you, is extremely important. Operating this motorcycle safely is an important responsibility. Crossfire Motorcycle Pty Ltd. has provided operating procedures and other information on labels and in this manual to help you make informed decisions about safety. This information will alert you to potential hazards that could harm you or others.
  • Page 8 Never ride your motorcycle without a helmet. Even a crash at slow speed can result in a fatal head injury if you are not wearing a helmet. Crossfire recommends wearing helmets that have been certified for safety by helmet testing organizations that are independent from the helmet manufacturer.

  • Page 9: Safety Information For Parents

    Follow all instructions in this owner‟s manual regarding modifications and accessories. Crossfire Corp. strongly recommends that you do not remove any original equipment or modify your motorcycle in any way that may alter the design and/or operation. Such a change could drastically impair the stability, handling, acceleration, and braking capabilities of the motorcycle and cause a crash.

  • Page 10: Safety Label Information

    Others will provide important safety and maintenance information. Please read them carefully and do not remove them. If your label wears off from riding or becomes hard to read, contact your Crossfire dealer for a replacement.

  • Page 11: Component Locations

    COMPONENT LOCATIONS When you ride a motorcycle off-road, you need to be able to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Please read this section carefully before you ride your motorcycle. This section of the manual will describe the function, location, and operation of all the basic controls of your motorcycle.
  • Page 12 COMPONENT LOCATIONS Battery CDI Box Spark Plug Kick Starter Oil Filter Rear Brake Pedal Air Filter Fuel Valve Chassis Number Drive Chain Shift Lever Engine Number Side Stand...

  • Page 13: Serial Number Locations

    SERIAL NUMBER LOCATIONS VIN – Chassis Number The VIN number is located in one of three places on the chassis. Right Side of frame. Left side of frame. Steering head tube. Write this number in the VIN box on page 3. Engine Model &...

  • Page 14: Operating Controls

    OPERATING CONTROLS Stop Switch The stop switch turns off the engine. When this button is pressed, the ignition circuit is turned off. Start Switch The start switch turns on the engine. When this button is pressed, the engine will start. Once started, release the button.
  • Page 15 OPERATING CONTROLS Choke Lever (XZ250R – V4) When pulling the choke lever toward you, a cylinder in carburetor is opened. Through this cylinder, the engine can take in additional fuel. This results in a rich fuel and air mixture, which is needed for a cold start. When releasing the choke lever, the cylinder is closed again.

  • Page 16: Operating Controls

    OPERATING CONTROLS Kick Start Lever The kick start lever is mounted on the right side of the engine. It is used to start the engine in case the electrical starter system is non-functional. Side Stand Push the side stand to the ground and tilt the motorcycle to the left.

  • Page 17: Before Riding

    BEFORE RIDING Before you ride, you must be absolutely sure that you and your motorcycle are ready to ride. To help you get prepared, this section of the manual will discuss how to evaluate your riding readiness and how to perform our recommended ore-ride inspection of your motorcycle.

  • Page 18: Is The Motorcycle Ready To Ride

    Brakes – Step on the rear brake lever and squeeze the front brake lever to be sure the brakes are working properly. Remember, be sure to take care of any problems you find or have your Crossfire dealer correct it before you ride.

  • Page 19: Basic Operation & Riding

    2. Make sure the transmission is in the neutral position. 3. Turn the fuel tap to the “ON” position (Pg. 12). 4. Pull and hold the choke lever (Pg. 13). (XZ250R V4) 5. Lift the choke lever up (Pg.15). (XZ250R-LC) (XZ250R-ZS) 6.

  • Page 20: Flooded Engine

    2. Make sure the transmission is in the neutral position. 3. Turn the fuel tap to the “ON” position (Pg. 12). 4. Pull and hold the choke lever (Pg. 13). (XZ250R V4) 5. Lift the choke lever up (Pg.15). (XZ250R-LC) (XZ250R-ZS) 6.

  • Page 21: Shifting Gears

    SHIFTING GEARS This motorcycle has five (5) forward gears for the LC & ZS engines and V4 Engine six (6) forward gears for the V4 engine. To start riding, after the engine has been warmed up LC / ZS Engine and the side stand raised: 1.

  • Page 22: Braking Technique

    BRAKING TECHNIQUE This section will cover basic braking technique for your motorcycle. To slow or stop the motorcycle, squeeze and hold the clutch lever and apply the front brake lever and rear brake pedal firmly and smoothly. If your speed is reduced a significant amount, you may need to downshift to a lower gear. Gradually increase your braking pressure as you feel it is needed.

  • Page 23: Maintaining Your Dirt Bike

    In this section you will also find important safety precautions, information on oils, and tips for keeping your Crossfire looking good.

  • Page 24: Maintenance Schedule

    Crossfire dealer. If you decide to do your own maintenance, use only replacement parts that you have purchased from an Crossfire dealer or parts purchased directly from Crossfire. This will ensure the best quality and reliability for your motorcycle.

  • Page 25: Basic Maintenance Precedures

    The engine in your motorcycle has been designed to run on any gasoline with a pump octane rating of 86 or higher. Most service stations will display the octane rating above each pump. Although it is not required, Crossfire recommends use of gasoline with a 90 octane rating or higher to ensure maximum performance and reliability.

  • Page 26: Cooling System

    4. Make sure the overflow tube is connected and not clogged. 5. Check the radiator fins to make sure they are not clogged. 6. If you do notice any leaks at any time, consult your nearest Crossfire dealer. WARNING Coolant Replacement...

  • Page 27: Engine Oil

    BASIC MAINTENANCE PROCEDURES ENGINE OIL Using proper oil, and regularly checking, adding and changing oil will help extend the service life of your engine. Even the best oil wears out and becomes thinner. Changing oil helps get rid of dirt and deposits in the engine.
  • Page 28 DO NOT screw it back in. 5. Check that the oil level is within the (1) & (2) hash- XZ250R V4 marks on the dip stick as in Fig. 1 6. If the oil level is at or near the upper mark (1), you do not need to add oil.

  • Page 29: Changing Oil & Filter

    18. Install the filter cover, be careful not to damage the O- ring, tighten the filter cover bolts to 9ft lbs. (12 Nm). 19. For the XZ250R V4 engine series, there are 2 screen filters that also need to be replaced when doing an oil change.

  • Page 30: Changing Air Filter

    Always replace the air filter with a genuine Crossfire filter specifically designed for your model or a filter of equal quality. Failure to maintain the filter can/may cause engine wear or damage, expensive repairs, low engine power, low fuel mileage, carbon build up on valves and foul the spark plug.

  • Page 31: Throttle System

    BASIC MAINTENANCE PROCEDURES THROTTLE THROTTLE FREEPLAY A. Throttle free-play should be 3 – 5 mm (0.10 – 0.20 in) B. If your throttle has more play than specified, adjustments need to be made. Follow the steps below: C. Minor adjustments are generally made with the upper adjuster.

  • Page 32: Engine Idle Speed

    Fig. 2. Only in different locations 9. The idle must be at 1500 ± 100 Rpm. 10. DO NOT adjust the air/fuel mixture screw . It has Fig. 2 been set from the factory. This should only be adjusted by an Crossfire dealer.

  • Page 33: Clutch System

    BASIC MAINTENANCE PROCEDURES CLUTCH SYSTEM In order to ensure the best performance and durability from the clutch, always be sure you have proper clutch free-play. Free-play is needed to ensure that the clutch has room for wear. A clutch with no free-play will begin to slip as the discs wear down.

  • Page 34: Clutch System

    5. Gradually release the clutch lever and open the throttle. XZ250R - LC The motorcycle should move smoothly and accelerate gradually. 6. If you cannot get the proper adjustment, see you Crossfire dealer or service center. XZ250R - ZS XZ250R V4...

  • Page 35: Spark Plug

    5. Using moderate grit sandpaper (220-400), sand between the center electrode and the side electrode until all carbon and oil deposits are removed. Crossfire recommends that you use a spark plug cleaner or a new spark plug if the plug is very dirty.

  • Page 36: Braking System

    BASIC MAINTENANCE PROCEDURES BRAKEING SYSTEM Your motorcycle is equipped with hydraulic disc brakes on both the front and rear wheels. Hydraulic brakes require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders.

  • Page 37: Adding Brake Fluid

    6. Press the foot brake lever to be sure the brakes are working properly. 7. Check the brake hose and brake caliper for leaks. If you are unsure how to re-assemble a part, contact your Crossfire dealer for servicing information and/or servicing. NOTICE Be very careful not to spill brake fluid on painted surfaces or it will damage the paint.

  • Page 38: Brake Pads

    If one side has worn down more extensive than the other, consult your Crossfire dealer for a possible bad brake caliper. 4. If you are unsure how to replace the brake pads, please contact your nearest Crossfire dealer for assistance, or schedule your motorcycle for servicing.

  • Page 39: Suspension System

    Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your Crossfire dealer for service and/or inspection. Your Crossfire dealer is the most qualified to determine whether or not replacement parts or service is required.

  • Page 40: Rear Suspension Inspection

    Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your Crossfire dealer for service and/or inspection. Your Crossfire dealer is the most qualified to determine whether or not replacement parts or service is required.

  • Page 41: Rear Suspension Adjustment

    BASIC MAINTENANCE PROCEDURES REAR SUSPENSION Cont. The rear suspension of your motorcycle has 3 different adjustment points. It comes from the factory set to the softest setting. If you wish to make the rear suspension harder, follow the procedure below. Adjusting the rear shock is not hard, but like the front forks, changes should be made one at a time to gain an accurate understanding of how they affect the bike.
  • Page 42 DO NOT TRY TO REPAIR THE SHOCK. 4 positions. IF REPAIR IS NECESSARY, TAKE THE 3. To adjust to the standard position, turn the adjuster MOTORCYCLE TO A CROSSFIRE DEALER. clockwise until it will no longer turn (DO NOT FORCE). This is the full hard setting.

  • Page 43: Rims, Tires & Spokes

    Look for a wobble in the wheel. If a wobble is evident, the wheel is not“true”. See your Crossfire dealer or local motorcycle shop for inspection. TIRE AIR PRESSURE Properly inflated tires will provide you with the best combination of handling, tread life, and riding comfort.

  • Page 44: Tire Inspection

    Always use replacement tubes that are the same size as the original. We recommend that you have tubes changed at your local Crossfire dealer or your local motorcycle shop. Replacing a tube requires removal and installation of the wheel. Anytime you have a tube replaced, perform the tire inspection listed at the top of this page.

  • Page 45: Drive Chain System

    This indicates that the chain is worn beyond its service limit. 5. Inspect the front and rear sprockets for excessive wear or damage. Refer to the illustration at the top of page 42. If needed, replace any worn or damaged sprockets. See your Crossfire dealer for assistance. NOTICE...

  • Page 46: Drive Sprocket Inspection

    3. If the roller has been worn down beyond the two points marked in Fig. 1, then the roller(s) must be replaced. 4. If you cannot or do not know how, take the motorcycle to a Crossfire dealer for service. CAUTION NEVER RIDE YOUR MOTORCYCLE IF THE ROLLERS ARE WORN EXCESSIVELY.

  • Page 47: Chain Slider Inspection

    BASIC MAINTENANCE PROCEDURES CHAIN SLIDERS CHAIN SLIDER INSPECTION 1. Check the slider for wear Fig. 1 2. If the wear limit has been reached Fig. 3, it must be replaced. Fig. 1 1. Check the guide slider for wear Fig 2. 2.

  • Page 48: Chain Adjustment

    BASIC MAINTENANCE PROCEDURES CHAIN ADJUSTMENT Follow the procedure below to adjust the drive chain slack. Be sure that you are parked on a level surface and the engine is turned OFF. CHAIN ADJUSTMENT 1. Loosen the rear axle nut 2. Loosen the lock nut on both right and left side.

  • Page 49: Chain Removal & Replacement

    Replace the drive chain if it has any damaged rollers, loose fitting links, or otherwise appear unserviceable. 4. Inspect the sprockets for wear or damage. Crossfire recommends that you replace the sprockets when you install a new drive chain. 5. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link.

  • Page 50: Troubleshooting

    No hard firmness in the kick start lever means you have poor compression. Is the compression normal? - Valve stuck open/seized or improper valve timing (see your Crossfire dealer) - Worn cylinder wall and/or piston rings (replace engine)
  • Page 51 Cylinder Compression Inspection - Check the cylinder compression. Is the engine compression normal? - Valve stuck open/seized or improper valve timing (see your Crossfire dealer) - Worn cylinder wall and/or piston rings (replace engine) - Leaking or damaged cylinder head gasket (see your Crossfire dealer)
  • Page 52 - Excessive carbon buildup in the combustion chamber Ignition Timing Inspection - See your local Crossfire dealer or motorcycle repair shop to have the ignition timing and engine lubrication system inspected. Only attempt these procedures if you are qualified and have the proper tools needed.

  • Page 53: Poor Performance At High Speed

    - Carburetor is not serviced frequently enough, contaminated fuel Ignition Timing & Valve train Inspection - See your local Crossfire dealer or motorcycle repair shop to have the ignition timing inspected. Only attempt these procedures if you are qualified and have the proper tools needed.

  • Page 54: Troubleshooting

    TROUBLESHOOTING POOR HANDLING Steering is heavy - Steering stem nut too tight - Damaged steering head bearings - Check tire pressure Either wheel has a Wobble - Excessive wheel bearing play - Bent Rim - Improperly installed wheel hub - Damaged swing-arm - Bent frame - Loose or broken spokes - Old tires with “dry-rot”...

  • Page 55: Resolving The Unexpected

    RESOLVING THE UNEXPECTED GENERAL GUIDELINES If you encounter trouble during a ride, the first thing you should do is stop as soon as it is safely possible. Do not continue to ride if you have a flat tire, if you hear an unusual noise, or if your motorcycle just does not feel right.

  • Page 56: Resolving The Unexpected

    Sometimes crash damage is hidden or not immediately apparent. Once you get home, go over your motorcycle thoroughly and fix any problems that you find. Also, be sure to have your Crossfire dealer inspect the frame and suspension after a serious crash.
  • Page 57 TORQUE SPECIFICATIONS...
  • Page 58 TORQUE SPECIFICATIONS Torque Torque Name Notes Name Notes N•m ft•lbs N•m ft•lbs Brake hose bolt 32.4 Seat bolts 24.4 Brake reservoir cap Brake hose bolt 32.5 Triple clamp (upper) Exhaust mounting bolt 24.4 Triple clamp (lower) Sub-frame bolt (upper) 33.8 Handlebar riser (lower) 37.8 Shock spring lock nut...
  • Page 59 TORQUE SPECIFICATIONS XZ250R - LC Torque Name Notes N•m ft•lbs Engine, Front Oil Drain Cap 17.5 Engine mount (lower) 40.5 Sprocket Bolts 16.2 Swing Arm bolt Engine mount (upper) Engine, Top Brake Lever 29.7 Kick Starter 33.7 Exhaust 20.2 Water Pump Oil Filter 10.8 Starter Gear Cover...
  • Page 60 TORQUE SPECIFICATIONS XZ250R - ZS Torque Name Notes N•m ft•lbs Engine, Front Oil Drain Bolt 17.5 Engine mount (lower) 40.5 Sprocket Bolts 16.2 Swing Arm bolt Engine mount (upper) Engine, Top Brake Lever 29.7 Kick Starter bolt 33.7 Exhaust nut 20.2 Oil Filter 10.8...
  • Page 61 TORQUE SPECIFICATIONS XZ250R – V4 Torque Name Notes N•m ft•lbs Engine mount (top) DO NOT REMOVE //// //// //// Engine mount (upper) 40.5 Sprocket cover bolts 16.2 Sprocket bolt 48.6 Engine mount (lower) 40.5 Oil filter screen 13.5 Oil drain bolt 17.5 Swing arm bolt Kick starter bolt...

  • Page 62: Specifications

    SPECIFICATIONS XZ250R - LC XZ250R - ZS XZ250R V4 Engine Loncin - LC170MM-2A Zongshen - ZS167MM Zongshen - ZS177MM 4 - Stroke Water Cooled / 4 Design 4 - Stroke Water Cooled / 2 Valve / Single Camshaft Valve Displacement 232.6 mL...
  • Page 63 SPECIFICATIONS XZ250R - LC XZ250R - ZS XZ250R V4 Frame High Strength Steel Forks T7 Series, Inverted, Dual Adjustable 910mm Wheel Travel Front T7 Series, Dual Adjustable 245 mm // T8 Series 275 mm Rear T8 Series 110 mm Rear Suspension...

  • Page 64: Maintenance Records

    MAINTENANCE SCHEDULE RECORD Odometer or Hour Reading Odometer or Hour Reading Odometer or Hour Reading 00,000 Dealer Stamp Dealer Stamp Dealer Stamp Date Date Date Signature Signature Signature Odometer or Hour Reading Odometer or Hour Reading Odometer or Hour Reading Dealer Stamp Dealer Stamp Dealer Stamp...

  • Page 65: Notes

    NOTES...
  • Page 66 NOTES...

This manual is also suitable for:

Xz250r-zxXz250r-lc

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