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KLX250R
Kawasaki
KLX250
Motorcycle
Service Manual
Third Edition (2): Jul. 29, 1997 (K)
© Kawasaki Heavy Industries. Ltd. 1993,1994,1996

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Table of Contents

   Also See for Kawasaki KLX250, KLX250R

   Summary of Contents for Kawasaki KLX250, KLX250R

  • Page 1 KLX250R Kawasaki KLX250 Motorcycle Service Manual Third Edition (2): Jul. 29, 1997 (K) © Kawasaki Heavy Industries. Ltd. 1993,1994,1996...
  • Page 2: List Of Abbreviations

    LIST OF ABBREVIATIONS ampere(s) pound(s) A B D C after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal (s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution...
  • Page 3: General Information

    , could result in personal nance. injury, or loss of life. • Use proper tools and genuine Kawasaki "JET SKI" watercraft parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki "JET SKI"...
  • Page 4 This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of partic- ular interest for more efficient and convenient operation. • Indicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it follows.
  • Page 5 United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance w i t h applicable regulations of the California Air Resources Board on vehicles sold in California only.
  • Page 6 NOTE o The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2.
  • Page 7: Fuel System

    Quick Reference Guide General Information Fuel System Cooling System Engine Top End Engine Right Side/Left Side Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix This quick reference guide will assist you in Supplement -1994 Models locating a desired topic or procedure.
  • Page 8: Table Of Contents

    GENERAL INFORMATION General Information Table of Contents Before Servicing Model Identification 1 -4 General Specifications 1 -6 Periodic Maintenance Chart - KLX250D 1-10 Periodic Maintenance Chart - KLX250E 1 -12 Torque and Locking Agent 1 -14 Special Tools and Sealant 1-17 Cable, Wire and Hose Routing 1 -23...
  • Page 9: General Information

    GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
  • Page 10 GENERAL I N F O R M A T I O N (12) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
  • Page 11: Model Identification

    GENERAL INFORMATION Model Identification KLX250-D1 KLX250-D2 KLX250-D3 KLX250-D4...
  • Page 12 GENERAL INFORMATION KLX250-E1 KLX250-E2 KLX250-E3...
  • Page 13: General Specifications

    GENERAL INFORMATION General Specifications Items KLX250-D1, D2, D3, D4 Dimensions: Overall length 2115 mm Overall width 910 mm Overall height 1220 mm Wheelbase 1435 mm Road clearance 320 mm Seat height 925 mm Dry weight 104 kg Curb weight: Front 53 kg Rear 59 kg...
  • Page 14 GENERAL INFORMATION KLX250-D1, D2, D3, D4 Items Drive Train: Primary reduction system: Gear Type 2.863 (63/22) Reduction ratio Wet multi disc Clutch type Transmission: 6-speed, constant mesh, return shift Type 3.000 (30/10) Gear ratios: 1 st 2.000(30/15) 1.500 (27/18) 1.250 (25/20) 1.050 (21 /20) 0.904 (19/21) Final drive system:...
  • Page 15 GENERAL INFORMATION Items KLX250-E1, E2, E3 Dimensions: Overall length 2135 mm, (FG)(NR) 2220 mm (IT) 2170 mm Overall width 870 mm Overall height 1210 mm Wheel base 1440 mm Road clearance 300 mm 890 mm Seat height Dry weight 115 kg Curb weight: Front 60 kg...
  • Page 16 GENERAL INFORMATION KLX250-E1, E2, E3 Items Drive Train: Primary reduction system: Gear Type Reduction ratio 2.863 (63/22) Clutch type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear ratios: 3 . 0 0 0 ( 3 0 / 1 0 ) 2.000 (30/15) 1.500(27/18) 1.250 (25/20)
  • Page 17: Periodic Maintenance Chart - Klx250d

    1-10 GENERAL INFORMATION Periodic Maintenance Chart - KLX250D The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. ENGINE Clutch -- adjust Clutch and friction plates -- check* Throttle cables -- adjust Spark plug -- clean, gap* Valve clearance -- check* Air cleaner element -- clean...
  • Page 18 GENERAL I N F O R M A T I O N 1-11 FREQUENCY FREQUENCY Traveled Distance km (mi) (60) OPERATION OPERATION Rear sprocket -- check* • (300) • Wheel bearing -- check* 1000 • • • (600) Swingarm and uni-trak linkage pivots -- grease •...
  • Page 19: Periodic Maintenance Chart - Klx250e

    1-12 G E N E R A L I N F O R M A T I O N Periodic M a i n t e n a n c e C h a r t - KLX250E The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
  • Page 20 GENERAL INFORMATION 1-13 Steering stem bearing -- lubricate Front fork oil -- change Tire wear -- check* Spoke tightness and rim runout -- check* Swingarm pivot, uni-trak linkage -- lubricate General lubrication -- perform Nut, bolt, and fastener tightness -- check* ( t ) : For higher odometer readings, repeat at the frequency interval established here.
  • Page 21: Torque And Locking Agent

    1-14 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasekt. Letters used in the "Remarks" column mean: : Apply a non-permanent locking agent to the threads. LG : Apply liquid gasket to the threads.
  • Page 22 GENERAL INFORM ATION 1-15 Fastener Fastener Torque Remarks Remarks N - m kg-m ft-lb Engine Lubrication System: Engine Oil Drain Plug 11.0 Oil Pressure Relief Valve 11.0 Oil Pipe Banjo Bolts 87 in-lb 14.5 0.55 Oil Pump Mounting Screws 48 in-lb Engine Removal/Installation: Swing Arm Pivot Shaft Nut Engine Mounting Nuts...
  • Page 23 1-16 GENERAL INFORMATION Fastener Fastener Torque Remarks Remarks N - m k g - m f t - l b Swing Arm Pivot Shaft Nut Rocker Arm Pivot Nut 10.0 Tie-Rod Mounting Nuts[Upper, Lower] Steering: Handlebar Clamp Bolts 18.0 Steering Stem Head Nut Front Fork Upper Clamp Bolts 14.5 Front Fork Lower Clamp Bolts...
  • Page 24: Special Tools And Sealant

    GENERAL INFORMATION 1-17 Special Tools and Sealant Piston Ring Pliers: 57001-115 Outside Circlip Pliers: 57001 -144 Bearing Puller: 57001-135 Oil Pressure Gauge, 10 kg/cm : 57001 -164 Bearing Puller Adapter: 57001 -136 Fork Cylinder Holder Handle: 57001 -183 Steering Stem Bearing Driver: 57001-137 Compression Gauge: 57001 -221 Inside Circlip Pliers: 57001 -143 Valve Spring Compressor Assembly: 57001 -241...
  • Page 25 1-18 GENERAL INFORMATION Oil Seal Guide, 016: 57001 -263 Spark Plug Wrench, Hex 18: 57001 -1024 Oil Seal Guide, 013: 57001 -264 Fork Cylinder Holder Adapter: 57001 -1057 Piston Pin Puller Assembly: 57001-910 Rim Protector: 57001-1063 Hand Tester: 57001-983 Bead Breaker Assembly: 57001 -1072 Fuel Level Gauge: 57001-1017 Steering Stem Bearing Driver Adapter: 57001-1074...
  • Page 26 GENERAL INFORMATION 1-19 Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Driver: 57001 -1076 Hook Wrench: 57001-1101 Spring Compressor: 57001-1087 Head Pipe Outer Race Driver: 57001-1106 Piston Ring Compressor Grip: 57001 -1095 Head Pipe Outer Race Remover: 57001 -1107 Piston Ring Compressor Belt, $67 ~ <D79: 57001 -1097 Valve Seat Cutter, 45°...
  • Page 27 1-20 GENERAL INFORMATION Valve Seat Cutter, 45" - $27.5: 57001 -1114 Bearing Driver Set: 57001 -1129 Valve Seat Cutter, 32° - 028: 57001 -1119 Crankshaft Jig: 57001-1174 Valve Seat Cutter, 32° - 030: 57001 -1120 Oil Pressure Gauge Adapter, M10 x 1.25: 57001 -1182 Rotor Holder: 57001-1184 Valve Seat Cutter, 60°...
  • Page 28 GENERAL INFORMATION 1-21 Valve Spring Compressor Adapter, <P22: 57001 -1202 Pilot Screw Adjuster, A: 57001 -1239 Rotor Puller, M16/M18/M20/M22 x 1.5: 57001-1216 Timing Light: 57001-1241 Fork Outer Tube Weight: 57001 -1218 Front Fork Oil Seal Driver: 57001 -1219 Spark Plug Wrench, Hex 16: 57001 -1262 Jack: 57001-1238 Bearing Remover Shaft: 57001-1265...
  • Page 29 1-22 GENERAL INFORMATION Bearing Remover Head, 010 x 012: 57001 -1266 Fork Piston Rod Puller, M10 x 1.0: 57001 -1298 Bearing Remover Head, 015 x 017: 57001 -1267 Flywheel Holder: 57001 -1313 Fork Spring Holder: 57001-1286 Compression Gauge Adapter, M10 X 1.0: 57001 -1317 Fork Cylinder Holder: 57001 -1287 Valve Seat Cutter, 60°...
  • Page 30: Cable, Wire And Hose Routing

    GENERAL INFORMATION 1-23 Cable, Wire and Hose Routing Model: KLX250D 1. Reservoir Tank Hose 2. Tie-laps 3. Clamps Headlight 2. To Right Handlebar Switch 3. To Engine Stop Switch 4. Clamp, located on left top radiator Damper 6. Ignition Coil Main Harness 8.
  • Page 31 1-24 GENERAL INFORMATION 1. Throttle Cable M o d e l : KLX250E/F 2. Speedometer Cable 3. Clutch Cable 4. Front Brake Hose A u s t r a l i a M o d e l...
  • Page 32 GENERAL INFORMATION 1-25 M o d e l : KLX250E/F 11. Fasten the Lead so as to no slack with Clamp 1. To Right Handlebar Switch 12. LH Turn Signal Light Lead 2. Horn 13.R.H Turn Signal Light Lead 3. Hang on the hook 4.
  • Page 33 1-26 GENERAL INFORMATION 1. Fasten the Harness and Clamp with together S e c t i o n A 2. Run the Lead through under the Meter Cable 3.To the Head Light 4.To the Position Light 5. Fasten Harness white mark w i t h tie-lap(92072-1288 with ring) and hang the hole of...
  • Page 34 FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View Specifications Throttle Grip and Cables Free Play Inspection Free Play Adjustment Cable Installation Notes Cable Lubrication Cable Inspection Carburetor Idle Speed Inspection Idle Speed Adjustment Service Fuel Level Inspection Service Fuel Level Adjustment Fuel System Cleanliness Inspection Removal Installation Notes...
  • Page 35: Fuel System

    FUEL SYSTEM Exploded View AD: Apply adhesive 1. Jet Needle 2. Pilot Screw 3. Pilot Jet 4. Main Jet 5. Needle Jet/Bleed Pipe 6. Fuel Filter 7. Fuel Level Sensor 8. Vacuum Valve...
  • Page 36: Specifications

    FUEL SYSTEM 2-3 Specifications KLX250D KLX250E Special Tools - Pressure Cable Luber: K56019-021 Jack: 57001-1238 Pilot Screw Adjuster, A: 57001-1239 Fuel Level Gauge: 57001-1017 (AR): Austria Model (NL): Netherlands Model (FG): Germany Model (ST): Switzerland Model...
  • Page 37: Throttle Grip And Cables

    2-4 FUEL SYSTEM Throttle Grip and Cables Free Play Inspection • Check the throttle grip free play. Throttle Grip Free Play Standard: 2 ~ 3 mm * l f the free play is improper, adjust the throttle cable. Free Play Adjustment •...
  • Page 38: Cable Inspection

    FUEL SYSTEM • Lubricate the cable [A] with a penetrating rust inhibitor. Special Tool - Pressure Cable Luber: k56019-021 Cable Inspection • With the throttle cable [A] disconnected at both ends, the cable should move freely within the cable housing. * l f cable movement is not free after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable.
  • Page 39: Carburetor

    2-6 FUEL SYSTEM Carburetor Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides. * l f handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged.
  • Page 40: Service Fuel Level Inspection

    FUEL SYSTEM 2-7 Service Fuel Level Inspection Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine (KLX250D) or turn the ignition switch OFF (KLX250E). 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.
  • Page 41: Fuel System Cleanliness Inspection

    2-8 FUEL SYSTEM • Bend the tang [A] on the float arm very slightly to change the float height. O Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 17.0 mm NOTE ODo not push the needle rod [B] in during the float height measure-...
  • Page 42: Installation Notes

    FUEL SYSTEM • Remove the following. Engine Breather Hose lower end (KLX250D) Regulator (KLX250D) Seat Fuel Tank • For KLX250D, remove the carburetor [A] to the left. • For KLX250E, remove the carburetor [A] upward. • Pull the hoses off the carburetor. •...
  • Page 43: Disassembly/assembly Notes

    2-10 FUEL SYSTEM Disassembly I Assembly Notes AWARNING Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine (KLX250D) or turn the ignition switch OFF (KLX2S0E). 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.
  • Page 44: Inspection

    FUEL SYSTEM 2-11 • Disassemble the carburetor. • Immerse all the metal parts in a carburetor cleaning solution. • Rinse the parts in water. • When the parts are clean, dry them with compressed air. • Blow through the air and fuel passages with compressed air. •...
  • Page 45: Air Cleaner

    2-12 FUEL SYSTEM Air Cleaner Housing Removal • Set the jack under the frame. Special Tool - Jack: 57001-1238 • Remove: Seat Side Covers Silencer Rear Fender Front Rear Fender Flap Igniter Engine Breather Hose Lower End [A] • Pull the air cleaner duct out of the carburetor. •...
  • Page 46: Element Cleaning And Inspection

    FUEL SYSTEM 2-13 Element Cleaning and Inspection NOTE Oln dusty areas, the element should be cleaned more frequently than the recommended interval. OAfter riding through rain or on muddy roads, the element should be cleaned immediately. O Since repeated cleaning opens the pores of the foam in the element, replace it with a new one in accordance with the Periodic Mainte- nance Chart.
  • Page 47: Fuel Tank 2 - 1

    2 - 1 4 F U E L S Y S T E M Fuel Tank Removal • Remove: Radiator Covers Seat •Turn the fuel tap to the OFF position. • Pull the fuel hose off the fuel tap. •Take the breather hose [A] off the handlebar(KLX250D). AWARNING Gasoline is extremely flammable and can be explosive under certain conditions.
  • Page 48: Cleaning

    FUEL SYSTEM 2-15 Cleaning AWARNING Clean the tank in a well-venrilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvents to clean the tank. •...
  • Page 49 COOLING SYSTEM Cooling System Table of Contents Radiator Removal 3-14 Exploded View Specifications Radiator Installation 3-14 Cooling System Radiator Inspection 3-14 Coolant Radiator Cap Inspection 3-14 Coolant Inspection Filler Neck Inspection 3-15 Coolant Deterioration: Water Hose, Breather Hose, Coolant Level: Air Vent Hose Inspection 3-15 Coolant Change...
  • Page 50: Exploded View

    3-2 COOLING SYSTEM Exploded View KLX250D T 1 : 7.8 N-m (0.8 kg-m, 69 in-lb) T2: 25 N-m (2.5 kg-m, 18ft-lb) T3: 9.8 N-m (1.0 kg-m, 87 in-lb)
  • Page 51 COOLING SYSTEM KLX250E...
  • Page 52: Specifications

    3-4 COOLING SYSTEM Specifications Items S t a n d a r d R e c o m m e n d e d C o o l a n t : Type Permanent type of antifreeze for aluminum engines and radiators Color Green Mixed ratio...
  • Page 53 COOLING SYSTEM 3-5 Cooling System The water cooling system is a pressurized forced circulation type. When the engine load varies, this system controls the engine temperature within narrow limits where the engine operates most efficiently. In this way the engine performs stably in various riding conditions, and possesses high durability.
  • Page 54: Coolant

    3-6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motorcycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart (see the General Information chapter). AWARNING To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot.
  • Page 55: Coolant Change

    COOLING SYSTEM Coolant Change The coolant should be changed periodically to ensure long engine life. Coolant Draining: AWARNING Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine or other painted parts.
  • Page 56: Air Bleeding

    3-8 COOLING SYSTEM Coolant Type : Permanent type antifreeze tor aluminum engines and radiators Color : Green Mixed ratio : Soft water 50%, coolant 50% Freezing point : -35°C(-31°F) Total amount : 1,6L • Install the reservoir tank on the frame. •...
  • Page 57: Coolant Leak Inspection

    COOLING SYSTEM 3-9 Coolant Leak Inspection Any time the system slowly loses coolant, inspect for leaks. •Visually check the water pump drainage outlet passage [A] for coolant leaks. * l f the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage.
  • Page 58: Cooling System Flushing

    3-10 COOLING SYSTEM Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the efficiency of the cooling system.
  • Page 59: Water Pump

    C O O L I N G S Y S T E M 3-11 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Draining). • Remove the cover bolts [A] and turn up the water pump cover [B] with the radiator hose attached.
  • Page 60: Impeller Inspection

    3-12 COOLING SYSTEM Impeller Inspection •Visually check the impeller [A]. * l f the surface is corroded, or if the blades [B] are damaged, replace the impeller. Mechanical Seal, Oil Seal Removal • Remove: Impeller Right Engine Cover (see Right Engine Cover Removal in the Engine Right Side/Left Side chapter) •...
  • Page 61: Mechanical Seal Inspection

    COOLING SYSTEM 3-13 • Apply plenty of high temperature grease to the oil seal [A] lips, and oil the oil seal outside circular surface. • Press the oil seal into the hole from the inside of the right engine cover w i t h a bearing driver set [B] so that the spring side of the seal lips is toward the inside of the cover.
  • Page 62: Radiator

    3-14 COOLING SYSTEM Radiator Radiator Removal • Remove the radiator cover. • Drain the coolant (see Coolant Draining). • Remove the fuel tank. • Loosen the hose clamps, and pull off the water and breather hoses. • Remove the mounting bolts, and take out the radiator with the radiator louver.
  • Page 63: Filler Neck Inspection

    • Install the cap [A]on a cooling system pressure tester [Bj. • Watching the pressure gauge, pump the tester to build up the test pressure. The cap must open at the specified relief pressure (the gauge hand flicks down). O Also, the cap must hold the relief pressure for at least 6 seconds. * l f the cap cannot hold the pressure, or the relief pressure is too high or too low, replace the cap with a new one.
  • Page 64: Radiator Fan (klx250e)

    3-16 COOLING SYSTEM Radiator Fan (KLX250E) Removal • Remove: Radiator Covers Seat Fuel Tank • Disconnect Fan Motor Lead Connector • Remove the fan motor [B] mounting bolts [A], and take off the fan motor. Installation Notes • Route the fan motor lead and the fan switch lead in accordance with the Cable, Wire and Hose Routing in the General Information chapter.
  • Page 65: Thermostat (klx250e)

    COOLING SYSTEM 3-17 Thermostat (KLX250E) Removal • Drain the coolant (see Coolant Change). • Remove the thermostat housing cap [A] bolts, and take the thermostat out of housing. Installation Note • Put the thermostat [A] into the housing so that the air bleeder hole [B] is positioned toward the rear of the engine.
  • Page 66: Thermostatic Fan Switch, Water Temperature Sensor (klx250e)

    The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to this part can damage it. Water Temperature Sensor Installation Notes •Apply silicone sealant (Kawasaki Bond: 56019-120) to the threads before installing the water temperature sensor. •Tighten the water temperature sensor.
  • Page 67 Cylinder Installation Notes 4 - 2 5 Camshaft Chain Wear 4-10 Piston Removal 4 - 2 5 KAWASAKI Automatic Compression Release Piston Installation Notes 4 - 2 6 (KACR) 4-11 Piston Ring, Piston Ring Groove Wear 4 - 2 7...
  • Page 68: Exploded View

    4-2 ENGINE TOP END Exploded View LS: Liquid Gasket (Silicone Sealant) M: Molybdenum Disulfide Grease O: Engine Oil S: Follow the specific tightening sequence T1: 7.8 N-m (0.80 kg-m, 69 in-lb) T2: 9.8 N-m (1.0 kg-m, 87 in-lb) T3:12 N-m (1.2 kg-m, 8.5 ft-lb) T4:15 N-m (1.5 kg-m, 11.0 ft-lb) T5: 20 N-m (2.0 kg-m, 14.5 ft-lb) T6: 46 N-m (4.7 kg-m, 34 ft-lb)
  • Page 69 ENGINE TOP END 4-3...
  • Page 70: Specifications

    4-4 ENGINE TOP END Specifications I t e m S t a n d a r d Service L i m i t C a m s h a f t : Cam height: Exhaust 36.25 ~ 36.35 mm 36.15 mm Inlet 36.25 ~ 36.35 mm 36.15 mm...
  • Page 71 ENGINE TOP END 4-5 Item Standard Service Limit Valve seat surface: Width: Exhaust 0.5 ~ 1.0 mm Inlet 0.5 ~ 1.0 mm 24.4 ~ 24.6 mm Outside diameter: Exhaust 28.4 ~ 28.6 mm Inlet Valve spring free length: Outer 41.4 mm 39.7 mm Inner 38.5 mm...
  • Page 72: Piston Ring Pliers:

    Valve Seat Cutter, 45° - $27.5: 57001-1114 Valve Seat Cutter, 32° - $28: 57001-1119 Valve Seat Cutter, 60° - $30: 57001-1123 Kawasaki Bond (Silicone Sealant): 56019-120 Valve Seat Cutter, 32° - $30: 57001-1120 Valve Seat Cutter, 45° - $24.5: 57001-1113 Valve Seat Cutter, 60°...
  • Page 73: Cylinder Head Cover

    • Installation is the reverse of removal. • Apply silicone sealant to the plug hole [A] of the cylinder head. •Tighten the cover bolts. Torque - Cover Bolts: 7.8 N-m (0.8 kg-m, 69 in-lb) Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 74: Camshaft Chain Tensioner

    4-8 ENGINE TOP END Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 75: Camshaft, Camshaft Chain

    ENGINE TOP END 4-9 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover Chain Tension Spring Camshaft Chain Tensioner • Remove the camshafts cap bolt [A], and take off the cap [B]. • Remove the camshafts. CAUTION The crankshaft may be turned, while the camshafts are removed. Always pull the chain taut while turning the crankshaft.
  • Page 76: Camshaft And Sprocket Assembly Notes

    4-10 ENGINE TOP END • Install the camshaft cap. •Tighten the cap bolts, following the tightening sequence shown in the figure. OThe sequence numbers are marked on the cap. • Install Cam Chain Tensioner (see this chapter) Cam Chain Tension Spring (see this chapter) Torque - Camshaft Cap Bolt 12 N-m (1.2 kg-m, 8.5 ft-lb) CAUTION After this procedure, if any resistance is felt while turning over the...
  • Page 77: Kawasaki Automatic Compression Release (kacr)

    ENGINE TOP END 4-11 KAWASAKI Automatic Compression Release (KACR) Due to the simplicity of the mechanism, no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism: compression is not released during starting, compression is released during running.
  • Page 78: Compression Measurement 4 - 1

    4-12 ENGINE TOP END Cylinder Head Compression Measurement • Remove: Seat Radiator Covers • T h o r o u g h l y warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running.
  • Page 79: Installation Notes

    ENGINE TOP END 4-13 Camshaft Chain Tensioner Camshafts Cylinder Head Bracket Oil Pipe Mounting Bolt (loosen) Oil Pipe Upper Banjo Bolt (Remove the cylinder head bolts in the following order. (1) 6 mm Bolts [A] (2) 8mm Allen Bolts [B] >Remove the chain guide[C].
  • Page 80: Cleaning

    4-14 ENGINE TOP END Cleaning • Before installation, blow the oil passages [A] clean with compressed air.
  • Page 81: Valves

    E N G I N E T O P E N D 4 - 1 5 Valves Clearance Inspection NOTE O If the engine is hot wait until the engine cools. Valve clearance must be checked when the engine is cold (room temperature). •...
  • Page 82: Removal

    4-16 ENGINE TOP END Removal • Remove the cylinder head. • Remove the valve lifter and the shim. • Use the valve spring compressor assembly and the adapter to press down the valve spring retainer. Special Tools - Valve Spring Compressor Assembly: 57001-241 [A] Valve Spring Compressor Adapter, $22: 57001-1202 •...
  • Page 83 NOTE O Heat the area around the valve guide to about 120 ~ 150 °C (248 ~ 302 °F) Special Tool - Valve Guide Arbor, 04.5: 57001-1331 CAUTION Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage.
  • Page 84 4-18 ENGINE TOP END VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (with engine cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 85 ENGINE TOP END 4-19 VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (with engine cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 86: Guide Installation 4 - 2

    4-20 ENGINE TOP END Guide Installation • Drive the valve guide in from the top of the cylinder head until the circlip stops the guide from going in too far. NOTE OApply engine oil to the valve guide outer surface. Heat the area around the valve guide hole to about 120 ~ 150 °C (248 ~...
  • Page 87: Seat Cutter Operating Care

    ENGINE TOP END 4-21 Seat Cutter Operating Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purpose than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
  • Page 88 4-22 ENGINE TOP END OTo make the 32° grind, fit a 32° cutter to the holder, and slide it into the valve guide. OTurn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. CAUTION The 32°...
  • Page 89: Valve-to-guide Clearance Measurement

    ENGINE TOP END 4-23 Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 90 4-24 ENGINE TOP END Valve Seat Repair...
  • Page 91: Cylinder, Piston 4 - 2

    E N G I N E T O P E N D 4 - 2 5 Cylinder, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Pull off the water pump hose [ A ] . •...
  • Page 92: Piston Installation Notes 4 - 2

    4-26 ENGINE TOP END Piston Installation Notes •The arrow [A] on the top of the piston must point toward the front. •When installing a piston pin snap ring [B], compress it only enough to install it and no more. CAUTION Do not reuse snap ring, as removal weakens and deforms them.
  • Page 93: Piston Ring, Piston Ring Groove Wear 4 - 2

    ENGINE TOP END 4-27 Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seating. * T h e rings should fit perfectly parallel to the groove surfaces. If not, the piston must be replaced. •...
  • Page 94: Exhaust Pipe, Muffler 4 - 2

    4-28 ENGINE TOP END Exhaust Pipe, Muffler Exhaust Pipe Removal • Loosen the clamp bolt [A]. • Remove the exhaust pipe holder nuts [A]. • Pull off the exhaust pipe to the frontward. Muffler Removal • Remove the right side cover. •...
  • Page 95 ENGINE RIGHT SIDE/LEFT SIDE 5-1 Engine Right Side/Left Side Table of Contents Exploded View Specifications Clutch Cable Adjustment Check Clutch Adjustment Clutch Cover Clutch Cover Removal Clutch Cover Installation Notes Right Engine Cover Removal Clutch Removal: Clutch Installation Notes Friction and Steel Plate Wear, Damage Inspection Friction and Steel Plate Warp Inspection 5-10 Clutch Spring Free Length Measurement...
  • Page 96: Exploded View

    5-2 ENGINE RIGHT SIDE/LEFT SIDE Exploded View KLX250D/E G : Apply Grease Apply a non permanent locking agent T1: 5.4 N-m (0.55 kg-m, 48 in-lb) T2: 9.8 N-m (1.0 kg-m, 87 in-lb) T3: 15 N-m (1.5 kg-m, 11.0 ft-lb) T4: 78 N-m (8.0 kg-m, 58 ft-lb) T5: 3.2 N-m (0.33 kg-m, 29 in-lb) T6: 37 N-m (3.8 kg-m, 27 ft-lb)
  • Page 97 ENGINE RIGHT SIDE/LEFT SIDE 5-3 KLX250D/E...
  • Page 98: Specifications

    Special Tools - Oil Seal Guide, $16: 57001-263 Oil Seal Guide, $13: 57001-264 Kick Shaft Okl Seat Guide: 57001-267 Pressure Cable Luber: K56019-021 Flywheel Holder: 57001-1313 Outside Circlip Pliers: 57001-144 S e a l a n t - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 99: Clutch Cable

    ENGINE RIGHT SIDE/LEFT SIDE 5-5 Clutch Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the Periodic Maintenance Chart. To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.
  • Page 100: Clutch Cover

    ENGINE RIGHT SIDE/LEFT SIDE Clutch Cover Clutch Cover Removal • Drain the engine oil. • Remove the clutch cable bracket bolts [A], and then the cable lower end. • Unbolt the clutch cover bolts, and take off the clutch cover. CAUTION Do not remove the clutch release shaft [A] unless it is absolutely necessary.
  • Page 101: Right Engine Cover

    ENGINE RIGHT SIDE/LEFT SIDE 5-7 Right Engine Cover Removal • Remove : Engine Oil (drain) Coolant (drain) Kick Pedal Clutch Cable Lower End and Bracket Oil Pipe Banjo Bolt Brake Pedal and Spring Water Pump Cover (turn up) Impeller • T u r n the clutch release lever toward the rear and free the release shaft from the clutch spring plate pusher.
  • Page 102: Clutch

    5-8 ENGINE RIGHT SIDE/LEFT SIDE Clutch Removal: • Remove the clutch cover (see Clutch Cover Removal). • Remove the magneto flywheel cover. • Install the flywheel holder [A] on the magneto flywheel. NOTE O Use the flywheel holder to prevent the clutch from rotating. Special Tool - Flywheel Holder: 57001-1313 [A] •...
  • Page 103: Clutch Installation Notes

    ENGINE RIGHT SIDE/LEFT SIDE 5-9 Clutch Installation Notes • Installation is the reverse of removal. • Apply engine oil to the inside of the clutch housing gear and kickstarter driven gear. • Install the friction plates and steel plates, starting with a friction plate and alternating them.
  • Page 104: Friction And Steel Plate Warp Inspection

    5-10 ENGINE RIGHT SIDE/LEFT SIDE Friction and Steel Plate Warp Inspection • Place each friction plate or steel plate on a surface plate [C], and measure the gap between the surface plate and each friction plate or steel plate [A] with a thickness gauge [B]. The gap is the amount of friction or steel plate warp.
  • Page 105: Primary Gear

    ENGINE RIGHT SIDE/LEFT SIDE 5-11 Primary Gear Primary Gear Removal • Remove the right engine cover (see Right Engine Cover Removal). • Remove the clutch (see Clutch Removal). • Using the flywheel holder to prevent the primary gear [ A ] from rotating, loosen the primary gear nut [ B ] .
  • Page 106: Kickstarter

    5-12 ENGINE RIGHT SIDE/LEFT SIDE Kickstarter Kickstarter Assembly Removal • Remove: Right Engine Cover • Pull the end of the kick spring [A] o u t o f the hole [ B ] in the crankcase. • Pull off the kick shaft assembly [ A ] . Kickstarter Assembly Installation Notes •...
  • Page 107: Kickstarter Idle Gear Removal Note

    ENGINE RIGHT SIDE/LEFT SIDE 5-13 Kickstarter Idle Gear Removal Note • Remove the right engine cover and clutch housing before idle gear removal (see Right Engine Cover Removal and Clutch Removal). • Remove the idle gear circlip and pull off the idle gear. Kickstarter Idle Gear Installation Notes •Apply molybdenum disulfide grease to the inside of the idle gear [A].
  • Page 108: External Shift Mechanism

    5-14 ENGINE RIGHT SIDE/LEFT SIDE External Shift Mechanism Removal • Remove: Engine Sprocket Cover Engine Sprocket Shift Pedal Guard Shift Mechanism Cover • Pull out the external shift mechanism [A]. • Remove the nut [B], and takeoff the gear set lever [C]. Installation Notes •...
  • Page 109 ENGINE LUBRICATION SYSTEM 6 Engine Lubrication System Table of Contents Exploded View Specifications Engine Oil Flow Chart Engine Oil and Oil Filter Oil Level Inspection Oil and/or Oil Filter Change Oil Filter Removal Oil Filter Installation Notes Oil Pump and Relief Valve Relief Valve Removal Relief Valve Installation Notes Oil Pump Removal...
  • Page 110 6-2 ENGIIME LUBRICATION SYSTEM Exploded View KLX250D/E Relief Valve Oil Pump Engine Oil Drain Plug T1: 15 N-m(1.5 kg-m, 11.0 ft-lb) T2: 9.8 N-m(1.0 kg-m, 87 in-lb) T3: 20 N-m(2.0 kg-m, 14.5 ft-lb) T4: 5.4 N-m(0.55 kg-m, 48 in-lb)
  • Page 111: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM 6-3 Specifications Item Standard Engine Oil: SE or SF class Grade SAE 10W-40, 10W-50, 20W-40, or 20W-50 Viscosity Capacity 1.3 L (when filter is not removed) 1.4 L (when filter is removed). 1.5 L (when engine is completely dry) Oil Pressure Measurement: 430 ~ 590 kPa (4.4 - 6.0 kg/cm , 63 ~ 85 psi)
  • Page 112: Engine Oil Flow Chart

    6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil Screen 2. Oil Pump 3. Clutch Cover Oil Passage 4. Oil Filter 5. Crankshaft 6. Oil Pipe Banjo Bolt 7. Camshafts 8. Drive Shaft 9. Output Shaft 10. Camshaft Chain Tunnel...
  • Page 113: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A W A R N i N G Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection * l f the oil has just been changed, start the engine and run it for several minutes at idle speed.
  • Page 114: Oil Filter Removal

    ENGINE LUBRICATION SYSTEM • If the oil filter is to be changed, replace it with a new one. • Check the gasket at the drain plug for damage. • Replace the gasket with a new one if it is damaged. •...
  • Page 115: Oil Pump And Relief Valve

    ENGINE LUBRICATION SYSTEM Oil Pump and Relief Valve Relief Valve Removal • Remove the right engine cover. • Remove the relief valve [A] from the oil passage in the right engine cover. Relief Valve Installation Notes • Apply a non-permanent locking agent to the threads of the relief valve, and tighten it.
  • Page 116: Oil Pump Assembly Notes

    ENGINE LUBRICATION SYSTEM Oil Pump Assembly Notes • A p p l y a non-permanent locking agent to the threads of the oil pump cover screws. • Before installing the oil pump, be sure the shaft and rotors turn freely. Oil Pump Drive Gear Removal •...
  • Page 117: When The Engine Is Warmed Up

    ENGINE LUBRICATION SYSTEM 6-9 • Start the engine, and read the oil pressure gauge while running engine at various speeds. A normal relief valve keeps the maximum oil pressure between the specified values. Relief Valve Opening Pressure 430 ~ 590 kPa (4.4 ~ 6.0 kg/cm , 63 ~ 85 psi) •...
  • Page 118: Oil Pump Inspection

    6-10 ENGINE LUBRICATION SYSTEM Oil Pump Inspection • Disassemble the oil pump. • Visually inspect the oil pump body [A], outer [B] and inner [C] rotors, and cover [D]. * l f there is any damage or uneven wear, replace the rotors or the oil pump assembly.
  • Page 119: Oil Screen

    E N G I N E L U B R I C A T I O N S Y S T E M 6-11 Oil Screen Removal • Remove the right engine cover. • Pull out the oil screen [A]. Installation Note •...
  • Page 120: Oil Pipe

    6-12 ENGINE LUBRICATION SYSTEM Oil Pipe Main Oil Pipe Removal • Remove: Clutch Cable Lower End • Remove the banjo Bolts [A], and take off the pipe [B]. If the banjo bolt is removed while the engine is warm, hot engine oil If the banjo bolt is removed while the engine is warm, hot engine oil will drain through the oil passage;...
  • Page 121 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View Specification Engine Removal/Installation Removal Installation Notes...
  • Page 122 ENGINE REMOVAL/INSTALLATION Exploded View KLX250D/E T1: 29 N-m (3.0 kg-m, 22 ft-lb) T2:44 N-m (4.5 kg-m, 33 ft-lb) T3: 88 N-m (9.0 kg-m, 65 ft-lb)
  • Page 123 ENGINE REMOVAL/INSTALLATION Specification Special Tool - Jack: 57001-1238 Engine Removal/Installation Removal • Remove or disconnect (see appropriate chapter) : Engine Oil (drain) Coolant (drain) Seat Side Covers Fuel Tank Exhaust Pipe Carburetor Ignition Coil Water Hoses Radiators Clutch Cable Lower End Cylinder Head Bracket Engine Breather Hose Lower End Regulator...
  • Page 124 C R A N K S H A F T / T R A N S M I S S I O N Crankshaft / Transmission Table of Contents Exploded View Specifications Crankcase Splitting Assembly Crankshaft, Connecting Rod Removal Installation Notes Connecting Rod Big End Side Clearance Crankshaft Runout Crankshaft Alignment...
  • Page 125: Crankshaft / Transmission

    CRANKSHAFT / TRANSMISSION Exploded View KLX250E KLX250D/E Apply Grease Apply a Liquid Gasket Apply a non-permanent locking agent 12 N-m (1.2 kg-m, 8.5 ft-lb) 25 N-m (2.5 kg-m, 18 ft-lb) 37 N-m (3.0 kg-m, 27 ft-lb) 98 N-m (10.0 kg-m, 72 ft-lb) 9.8 N-m (1.0 kg-m, 87 in-lb)
  • Page 126 CRANKSHAFT / TRANSMISSION 8-3 KLX250D/E...
  • Page 127: Specifications

    6.05 ~ 6.20 mm 6.25 mm Special Tool - Outside Circlip Pliers: 57001-144 Bearing Puller: 57001-135 Bearing Puller Adapter: 57001-136 Bearing Driver Set: 57001-1129 Crankshaft J ig: 57001 -1174 Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104-002 Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 128: Crankcase

    C R A N K S H A F T / T R A N S M I S S I O N Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface while parts are being removed. •...
  • Page 129: Assembly

    • A p p l y liquid gasket to the mating surface of the left crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104-002 • Using a suitable tool on the right crankcase to press around the hole for the crankshaft, fit the crankcase halves together w i t h a press on the tool.
  • Page 130 CRANKSHAFT / TRANSMISSION • Remove the crankshaft jig from the flywheels. • Tighten the crankcase bolts starting w i t h the ones around the crankshaft, and then the farther ones. Torque - Crankcase Bolts: 9.8 N-m (1.0 kg-m, 87 in-lb) •...
  • Page 131: Crankshaft, Connecting Rod

    C R A N K S H A F T / T R A N S M I S S I O N Crankshaft, Connecting Rod Removal • Split the crankcase (see Crankcase Splitting). • Remove the transmission shafts (see Transmission Shaft Removal). •...
  • Page 132: Crankshaft Runout

    CRANKSHAFT / TRANSMISSION Crankshaft Runout • Set the crankshaft in a flywheel alignment jig or on V blocks, and place a dial gauge against the points indicated. • Turn the crankshaft slowly. The maximum difference in gauge readings is the crankshaft runout. * l f the runout at either point exceeds the service limit, align the flywheels so that the runout falls within the service limit.
  • Page 133: Balancer

    8-10 CRANKSHAFT / T R A N S M I S S I O N Balancer Balancer Removal • Split the crankcase. •Tap lightly up the balancer shaft with a rubber mallet to remove the balancer gear. NOTE O To tight the balancer gear backlash, two pieces of gear are used for the KLX250E balancer gear assembly.
  • Page 134: Transmission

    CRANKSHAFT / TRANSMISSION 8-11 Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Pull out the shift rod [A], and disengage the shift fork guide pins from the shift drum grooves. • Remove the shift drum [B]. • Remove the shift forks [C] from the transmission gears. •Take out the drive shaft [D] and output shaft [E] together, with their gears meshed.
  • Page 135: Shift Drum And Fork Installation Notes

    8-12 C R A N K S H A F T / T R A N S M I S S I O N •The output shaft gears can be identified by size; the largest diameter gear is 1 st gear, and the smallest is 6th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips and washers are properly in place.
  • Page 136: Shift Fork Guide Pin/shift Drum Groove Wear

    C R A N K S H A F T / T R A N S M I S S I O N 8-13 Shift Fork I Gear Groove Wear • Measure the thickness of the shift fork ears [ A ] , and measure the w i d t h [B] of the shift fork grooves in the transmission gears.
  • Page 137: Ball Bearing Wear

    8-14 CRANKSHAFT / TRANSMISSION Gear Dog I Gear Dog Hole Damage •Visually inspect the gear dogs [A] and gear dog holes [B]. "*• Replace any damaged gears or gears with excessively worn dogs or dog holes. Ball Bearing Wear • Check the ball and needle bearings in the crankcase. O Since the ball and needle bearing are made to extremely close tolerances, the wear must be judged by feel rather than measurement.
  • Page 138 W H E E L S / T I R E S Wheels/Tires Table of Contents Exploded View Specifications Wheels (Rims) Front Wheel Removal Front Wheel Installation Notes Rear Wheel Removal Rear Wheel Installation Notes Inspection Spoke Inspection Rim Inspection Axle Inspection Tires Air Pressure Inspection/Adjustment...
  • Page 139: 9-2 Wheels/tires

    9-2 WHEELS/TIRES Exploded View KLX250D/E T1:1.5 N-m(0.15 kg-m, 13 in-lb) T2: 88 N-m(9.0 kg-m, 65 ft-lb) T3: 98 N-m(10.0 kg-m, 72 ft-lb)
  • Page 140: Specifications

    WHEELS/TIRES Specifications I t e m S t a n d a r d Service L i m i t 0.5mm or less Rim runout: Axial 2 mm Radial 0.8 mm or less 2 mm Axle runout/100 mm 0.10 mm or less 0.2 mm 10 g or less Wheel balance...
  • Page 141: Wheels (rims)

    WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Using the jack under the frame, stabilize the motorcycle. Special Tool - Jack: 57001-1238 [A] • Remove: Speedometer Cable Lower End [A] Cotter Pin [B] • Loosen the axle nut [C]. • Remove the axle nut, pull out the axle and remove the wheel. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 142: Rear Wheel Removal

    WHEELS/TIRES Rear Wheel Removal • Raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Remove the clip from the master link using pliers, and free the drive chain from the rear sprocket. • Remove the cotter pin [ A ] . •...
  • Page 143: Inspection

    9-6 WHEELS/TIRES • Check the drive chain slack (see Drive Chain Slack Inspection in the Final Drive chapter). •Torque the following: Torque - Rear Axle Nut: 98 N-m (10 kg-m, 72 ft-lb) Rear Caliper Mounting Bolts: 25 N-m (2.5 kg-m, 18 ft-lb) •...
  • Page 144: Rim Inspection

    WHEELS/TIRES Rim Inspection • Place the jack under the frame so that the front/rear wheel is raised off the ground. Special Tool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warping. * l f there is any damage to the rim, it must be replaced. •...
  • Page 145: Tires

    9-8 WHEELS/TIRES Tires Air Pressure Inspection I Adjustment • Using an air pressure gauge [ A ] , measure the tire air pressure w h e n the tires are cold. * Adjust the tire air pressure according to the following specifications, if necessary.
  • Page 146: Removal

    WHEELS/TIRES Removal CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. • Remove the wheel from the motorcycle (see this chapter). •...
  • Page 147: Hub Bearings

    9-10 WHEELS/TIRES Hub Bearings Removal Notes CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. •...
  • Page 148: Speedometer Gear Housing

    WHEELS/TIRES 9-11 Speedometer Gear Housing Disassembly and Assembly NOTE Olt is recommended that the assembly be replaced rather than attempting to repair the components. • Install the speedometer gear housing so that it fits in the speedometer gear drive notches (see Front Wheel Installation Notes). Lubrication •...
  • Page 149 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View 10-2 Specifications 10-3 Drive Chain 10-4 Drive Chain Slack Inspection 10-4 Drive Chain Slack Adjustment 10-4 Wheel Alignment Inspection 10-5 Wheel Alignment Adjustment 10-6 Drive Chain Wear Inspection 10-6 Drive Chain Lubrication 10-6 Drive Chain Removal 10-7...
  • Page 150: 10-2 Final Drive

    10-2 FINAL DRIVE Exploded View KLX250D/E KLX250E G: Apply Grease T1: 29 N-m (3.0 kg-m, 22 fl-lb)
  • Page 151: Specifications

    FINAL DRIVE 10-3 Specifications Item Standard Service Limit Drive Chain: Standard Chain KLX250D: Make DAIDO Type D.I.D. 520DS-6 Link 110 links KLX250E: Make ENUMA EK520LV-O Type Link 106 links Chain slack 55 ~ 65 mm Too tight: less than 55 mm Too loose: more than 70 mm 317.5 ~ 318.2 mm 323 mm...
  • Page 152: Drive Chain

    10-4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Stand the motorcycle with its side stand. • Check the wheel alignment (see Wheel Alignment Inspection), and adjust it if necessary (see Wheel Alignment Adjustment). NOTE O Clean the drive chain if it is dirty, and lubricate it if it appears dry. •...
  • Page 153: Wheel Alignment Inspection

    FINAL DRIVE 10-5 • Tighten the axle nut loosely, and tighten the left and right adjusting nuts slightly. Take care not to change the adjustment during the adjusting nut tightening. • Tighten the both chain adjuster locknuts securely. • T i g h t e n the axle nut. Torque - Axle Nut: 98 N-m (10 kg-m, 72 ft-lb) •...
  • Page 154: Wheel Alignment Adjustment

    10-6 FINAL DRIVE Wheel Alignment Adjustment This procedure is the same as Slack Adjustment. Drive Chain Wear Inspection • Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links. * l f there is any irregularity, replace the drive chain. •...
  • Page 155: Drive Chain Removal

    FINAL DRIVE 10-7 Drive Chain Removal • Remove the engine sprocket cover. • Remove the clip from the master link using pliers, and free the drive chain from the rear sprocket. Drive Chain Installation Notes • Installation is the reverse of removal. •...
  • Page 156: Sprocket

    10-8 FINAL DRIVE Sprocket Engine Sprocket Removal • Remove: Engine Sprocket Cover Circlip [A] • Remove the engine sprocket [B]. Engine Sprocket Installation Notes • Installation is the reverse of removal. • Replace the circlip with a new one. Rear Sprocket Removal •...
  • Page 157: Rear Sprocket Warp Inspection

    FINAL DRIVE 10-9 Rear Sprocket Standard: 237.54 ~ 238.04 mm/49T (KLX250D) 202.32 ~ 202.82/42T (KLX250E) Service Limit: 237.2 mm (KLX250D) 202.0 mm (KLX250E) NOTE O/f a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the chain. Rear Sprocket Warp Inspection •...
  • Page 158 BRAKES 11-1 Brakes Table of Contents Exploded View 11-2 Specifications 11 -4 Brake Lever, Brake Pedal 11 -5 Lever Play Adjustment 11 -5 Pedal Position/Pedal Play Adjustment 11 -5 Level Inspection 11-6 Change 11-6 Bleeding the Brake Line 11-7 Caliper 11-9 Front Caliper Removal 11 -9...
  • Page 159: 11-2 Brakes

    11-2 BRAKES Exploded View KLX250D/E G: Apply grease. T5: 5.9 N-m (0.6 kg-m, 52 in-lb) T1: 7.8 N-m (0.80 kg-m, 69 In-lb) T6: 9.8 N-m (1.0 kg-m, 87 in-lb) 72: 8.8 N-m (0.90 kg-m, 78 In-lb) T7: 23 N-m (2.3 kg-m, 16.5 ft-lb) T3:25 N-m (2.5 kg-m, 18.0 ft-lb) T8:17 N-m (1.75 kg-m, 12.7 ft-lb) T4:1.5 N-m (0.15 kg-m, 13 in-lb)
  • Page 160 BRAKES 11-3 KLX250D/E...
  • Page 161: Specifications

    11-4 BRAKES Specifications S t a n d a r d S e r v i c e L i m i t Item Brake Lever, Brake Pedal: Adjustable (to suit rider) Brake lever free play Pedal free play Non-adjustable Brake Fluid: Grade D.O.T.4...
  • Page 162: Brake Lever, Brake Pedal

    BRAKES 11-5 Brake Lever, Brake Pedal Lever Play Adjustment Adjust the front brake lever [A] to suit you. • Loosen the adjuster locknut [B] and turn the adjuster [C] to either side. • After adjustment, tighten the locknut. Pedal Position/Pedal Play Adjustment The brake pedal position and pedal play should not be adjusted.
  • Page 163: Level Inspection

    11-6 BRAKES Level Inspection In accordance with the Periodic Maintenance Chart, inspect that the brake fluid level in the front brake reservoir [A] is more than half full. NOTE O Hold the reservoir horizontal when checking brake fluid level. Check the brake fluid level in the front brake reservoir [A] is more than half full.
  • Page 164: Bleeding The Brake Line

    BRAKES 11-7 • Change the brake fluid as follows: O Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A] 2. Apply the brake and hold it [B] 3.
  • Page 165 11-8 BRAKES NOTE O The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs almost out any time during bleeding operation, the operation must be done over again from the beginning since air will have entered the line.
  • Page 166: Caliper

    BRAKES 11-9 Caliper Front Caliper Removal • Remove the front brake hose clamp mounting bolts. • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Remove the plug, and loosen the brake pad bolt [E] before the caliper removal if the caliper is to be disassembled.
  • Page 167: Disassembly

    11-10 BRAKES • Bleed the brake line (see Bleeding the Brake Line). • Check the brake for good braking power, no brake drag and no fluid leakage. AWARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc.
  • Page 168 BRAKES 11-11 • Replace the shaft rubber friction boot [A] and dust cover [B] if they are damaged. • Apply a thin coat of PBC (Ploy Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-resistant grease).
  • Page 169: Brake Pads

    11-12 BRAKES Brake Pads Removal • Remove the caliper cover. • Loosen the pad bolts. • Unscrew the caliper mounting bolts. • Detach the caliper from the disc. •Take the piston side pad [A] out of the caliper holder [B]. •...
  • Page 170: Master Cylinder

    BRAKES 11-13 Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately with a damp cloth. Front Master Cylinder Removal • Pull back the dust cover, and remove the banjo bolt [A] to disconnect the upper brake hose from the master cylinder (see Brake Hose Removal/Installation Notes).
  • Page 171: Rear Master Cylinder Installation Notes

    11-14 BRAKES •Take off the master cylinder mounting screws [D], and remove the master cylinder [E] with the reservoir. • Remove the reservoir cap, and pour the brake fluid into a container. I Remove the reservoir and its hose from the master cylinder. Rear Master Cylinder Installation Notes •...
  • Page 172: Assembly Notes

    BRAKES 11-15 Assembly Notes • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. • Apply brake fluid to the removed parts and to the inner wall of the cylinder. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 173: Brake Disc

    11-16 BRAKES Brake Disc Inspection •Visually inspect the disc. * l f it is scratched or damaged, replace the disc. • Measure the thickness of each disc at the point where it has worn the most. * Replace the disc if it has worn past the service limit. Thickness KLX250D: Front...
  • Page 174: Brake Hose

    BRAKES 11-17 Brake Hose Removal/Installation Notes CAUTION Brake fluid quickly ruins painted or plated surfaces; any spilled fluid should be completely wiped up immediately with damp cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 175 SUSPENSION 12-1 Suspension Table of Contents Exploded View 12-2 Guide Bushing Inspection 12-17 Specifications 12-4 Dust Seal Inspection 12-17 Front Fork 12-5 Spring Tension 1 2 - 1 7 Conventional Type 12-5 Rear Suspension (Uni-Trak) 1 2 - 1 8 Air Pressure Adjustment 12-5 Rear Shock Absorber:...
  • Page 176: Exploded View

    12-2 SUSPENSION Exploded View KLX250D/E Upside Down Type Apply Grease Apply a non-permanent Gasket Apply Molybdenum Disulfide Grease Apply Liquid Gasket 9.8 N-m (1.0 kg-m, 87 in-lb) 13 N-m (1.3 kg-m, 9.5 ft-lb) 20 N-m (2.0 kg-m, 14.5 ft-lb) 23 N-m (2.3 kg-m, 16.5 ft-lb) 29 N-m (3.0 kg-m, 22 ft-lb) 39 N-m (4.0 kg-m, 29 ft-lb) 54 N-m (5.5 kg-m, 40 ft-lb)
  • Page 177 SUSPENSION 12-3...
  • Page 178: Specifications

    12-4 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube diameter 43 mm Air pressure Atmospheric pressure (Non-adjustable) Compression damper setting 14th (AS: 12th) click from the first click of the fully clockwise position Fork oil viscosity KAYABA 01 or SAE5W Fork oil capacity Upside down...
  • Page 179: Front Fork

    S U S P E N S I O N 1 2 - 5 Front Fork Conventional Type Air Pressure Adjustment The standard air pressure in the front fork legs is atmospheric pressure. The air pressure in the front legs increases as the fork heats up, so the fork action will get stiffer as vehicle operation progresses.
  • Page 180: Fork Oil Change

    12-6 SUSPENSION • In this position, put the oil level gauge on the tube, and measure the distance from the top of the inner tube to the oil level. Special Tool - Fork Oil Level Gauge: 57001-1290 [A] Oil Level (fully compressed, without spring) Standard: 127 + 2 mm •Adjust the oil level as required within the specification using one of the...
  • Page 181: Front Fork Removal

    SUSPENSION 12-7 Front Fork Removal • Remove the caliper from the fork teg to be removed, and rest the caliper on some kind of stand so that it does not dangle. • Remove the front wheel (see Front Wheel RemovaJ Wheels/Tires chapter).
  • Page 182 12-8 SUSPENSION • Separate the inner tube from the outer tube as follows. O Remove the retaining ring [A] from the outer tube [B]. O Mount the front fork outer tube weight on the top of the outer tube by fitting the step of the weight to the top corner of the outer tube. Special Tool - Fork Outer Tube Weight: 57001-1218 O Holding the inner tube by hand in a vertical position, stroke the outer tube up and down several times and pull it down.
  • Page 183: Front Fork Assembly Notes

    SUSPENSION 12-9 Front Fork Assembly Notes • Assembly is the reverse of disassembly. • Check the O-ring at the top plug. Replace it w i t h a new one if damaged. • Replace the oil seal removed with a new one. •...
  • Page 184 12-10 SUSPENSION CAUTION If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube. Guide Bushing Inspection •Visually inspect the guide bushings [A], and replace them if necessary. Oil Seal and Dust Seal Inspection •...
  • Page 185: Oil Level Adjustment

    SUSPENSION 12-11 Compression Damping Adjustment • Clean the bottom of the fork tubes. • Remove the caps on the bottom of the fork tubes. • To adjust compression damping, turn the adjuster [A] on the front fork cylinder valve with the blade of a screwdriver until you feel a click. Adjust the compression damping to suit your preference under special conditions.
  • Page 186 12-12 SUSPENSION • Hold the fork tube upright, press the outer tube and the push rod all the way down. NOTE O The spring should not be installed. »Fill the front fork to the top with the specified oil. Recommended Oil KAY ABA 01 or SAE5W NOTE O While doing this, take care to keep the oil level topped off so that it...
  • Page 187 SUSPENSION 12-13 Oil Level (fully compressed, without spring) Standard: 97 ± 2 mm • Install the parts removed. Removal • Remove the fork protectors. • Remove the caliper from the fork leg to be removed, and rest the caliper on some kind of stand so that it does not dangle. •...
  • Page 188 12-14 SUSPENSION [A] Inner Tube [B] Cylinder Valve Assembly [C] O-ring [D] Gasket • Pull the push rod [A] and cylinder unit assembly [B] out the top of the outer tube [C]. • Separate the inner tube from the outer tube as follows. O Slide up the dust seal.
  • Page 189 SUSPENSION! 12-15 Assembly (Oil Change) Notes • Replace the following with new ones. Dust Seal [ A ] Retaining Ring [B] Oil Seal [C] Guide Bushings [D] • Place an oil coated plastic bag [E] over the end of the inner tube to protect the oil seals.
  • Page 190 12-16 SUSPENSION OScrew the rod nut [A] onto the push rod with the chamfered side [B] up. • Pour in the type and amount of fork oil specified and adjust the oil level (see Oil Level Adjustment in this chapter). •...
  • Page 191: Inner Tube Inspection

    SUSPENSION 12-17 Inner Tube Inspection • Visually inspect the inner tube, and repair any damage. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. * l f the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced.
  • Page 192: Rebound Damping Adjustment

    12-18 SUSPENSION Rear Suspension (Uni-Trak) Rear Shock Absorber: The rear suspension system of this motorcycle is Uni-trak. It consists of a rear shock absorber, swingarm, tie-rod and rocker arm. To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced w i t h an optional one (KLX250D).
  • Page 193: Spring Preload Adjustment (klx250d)

    SUSPENSION 12-19 Spring Preload Adjustment (KLX250D) • Remove the rear shock absorber (see Rear Shock Absorber Removal). • Clean the threaded portion on the upper end of the rear shock absorber. • Hold the lower end of the rear shock absorber in a vise. •...
  • Page 194: Installation Notes

    12-20 SUSPENSION •Then pull up and take out the rear shock absorber [A] from the left side of the frame. Installation Notes • T o r q u e the following. Torque - Rear Shock Absorber Mounting Nuts: 39 N-m (4.0 kg-m, 29 It-lb) Tie-Rod Mounting Nut: 81 N-m (8.3 kg-m, 60 ft-lb) Rocker Arm Pivot Nut 98 N-m (10.0 kg-m, 72 ft-lb)
  • Page 195: Disassembly (oil Change) Klx250d

    SUSPENSION 12-21 Disassembly (Oil Change) KLX250D The oil in the rear shock absorber should be changed at least once per racing season. The frequency for best performance must be based upon riding conditions and rider ability. • Remove the rear shock absorber from the frame (see Rear Shock Absorber Removal).
  • Page 196: Assembly Notes (klx250d)

    12-22 SUSPENSION • Pry or tap [B] at the gaps [A] in the stop with suitable tools to free the stop form the rear shock body. • Slide the stop up to the top of the push rod then lightly tap around the seal with a suitable rod and mallet, and push the seal assembly 10 mm down.
  • Page 197 SUSPENSION 12-23 AWARNING If weakened, deformed or flawed circlip is used, the gas reservoir cap may not hold when injecting the nitrogen gas. This would allow oil and internal parts to explode out of the reservoir. (Mount the circlip [A] in the groove in the gas reservoir. >...
  • Page 198: Spring Tension (klx250d)

    12-24 SUSPENSION • Check the circlip. * l f it is deformed or damaged, replace it with a new one. • Fit the circlip [A] into the groove in the rear shock body. AWARNING If the circlip is not a certain fit in the groove in the rear shock body, the push rod assembly may come out of the shock absorber when injecting the nitrogen gas or riding the motorcycle.
  • Page 199: Scrapping

    SUSPENSION 12-25 Scrapping AWARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber. Before a rear shock absorber is scrapped, release the nitrogen gas completely. Do not point the valve [A] toward your face or body. Swingarm Removal •...
  • Page 200: Tie-rod, Rocker Arm

    12-26 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Remove the tie-rod front mounting bolt [A]. CAUTION When pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a bolt could damage the bolt, sleeve, and bearing.
  • Page 201: Uni-trak Maintenance

    S U S P E N S I O N 1 2 - 2 7 Uni-trak Maintenance Check the uni-trak component parts for wear periodically, or whenever excessive play is suspected. • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 •...
  • Page 202 STEERING 13-1 Steering Table of Contents Exploded View 13-2 Specifications 13-3 Steering 13-4 Inspection 13-4 Adjustment 13-4 Stem, Stem Bearing Removal 13-5 Stem, Stem Bearing Installation 13-6 Steering Maintenance 13-8 Stem Bearing Lubrication 13-8 Stem Warp 13-8...
  • Page 203: 13-2 Steering

    13-2 STEERING Exploded View KLX250D/E G: Apply grease A D : Apply adhesive T l : 25 N-m (2.5 kg-m, 18.0 ft-lb) T2: 44 N-m (4.5 kg-m, 33 ft-lb) T3: 3.9 N-m (0.4 kg-m, 35 In-lb)
  • Page 204: Specifications

    STEERING 13-3 Specifications Special Tools - Steering Stem Bearing Driver: 57001-137 Steering Stem Bearing Driver Adapter: 57001-1074 Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver: 57001-1076 Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Driver: 57001-1106 Head Pipe Outer Race Remover: 57001-1107 Jack: 57001-1238...
  • Page 205: Inspection

    13-4 STEERING Steering Inspection • Place the jack under the engine so that the front wheel is raised off the ground. Special Tool - Jack: 57001-1238 • W i t h the front wheel pointing straight ahead, alternately nudge each end of the handlebar.
  • Page 206: Stem, Stem Bearing Removal

    STEERING 13-5 • Mount the handlebar clamps [B] so that the arrow [C] on the clamp point at the front [A]. OTorque the handlebar clamp bolts. Torque - Handlebar Clamp Bolts: 25 N-m (2.5 kg-m, 18 ft-lb) OTighten the clamp bolts, front first and then the rear. If the handlebar clamp is correctly installed, there will be no gap [A] at the front and a gap [B] at the rear after tightening.
  • Page 207: Stem, Stem Bearing Installation

    13-6 STEERING • Drive out the bearing outer races from the head pipe. O Remove the outer races passed into the head pipe, using the head pipe outer race remover [A], and hammer the head pipe outer race remover to drive it out. Special Tool - Head Pipe Outer Race Remover: 57001-1107 N O T E Olf either steering stem bearing is damaged, it is recommended that...
  • Page 208 STEERING 13-7 Special Tool - Steering Stem Nut Wrench: 57001-1100 [A] O Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged. O Again back out the stem locknut a fraction of a turn until it turns lightly. OTurn the stem locknut lightly clockwise until it just becomes hard to turn.
  • Page 209: Steering Maintenance

    13-8 STEERING Steering Maintenance Stem Bearing Lubrication • Remove the steering stem. • Using a high flash-point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. •Visually check the outer races and the roller.
  • Page 210 FRAME 14-1 Frame Table of Contents Exploded View 14-2 Fender 14-4 Front Fender Removal 14-4 Front Fender Installation Note 14-4 Rear Fender Front Removal 14-4 Rear Fender Front Installation Note 14-4 Rear Fender Rear Removal 14-4 Rear Fender Rear Installation Notes 14-5...
  • Page 211: Exploded View

    14-2 FRAME Exploded View KLX250E KLX250D/E 1. Side Cover Pads (R.H.) 2. Side Cover Pad (L.H.)
  • Page 212 FRAME 14-3 KLX250D/E KLX250E 3. Head Light Cover Seal 4. Air Cleaner Case 5. Speedometer Cable Clamp 6. Chain Case (FG): Germany Model...
  • Page 213: Fender

    14-4 FRAME Fender Front Fender Removal • Unscrew the mounting bolts [A], and remove the front fender. Front Fender Installation Note • Installation is the reverse of removal. Rear Fender Front Removal • Remove the seat. • Remove the rear fender front mounting bolts [A]. •...
  • Page 214: Rear Fender Rear Installation Notes

    F R A M E 14-5 • Remove the under cover [A] by taking off the bolts [B]. C Pull off the license light connectors. • Remove the rear fender rear section [A] by taking off the bolts [B] and nuts [C].
  • Page 215 ELECTRICAL SYSTEM -15-1 Electrical System Table of Contents Exploded View 15-2 Meter Mounting Inspection 15-20 Specifications 15-5 Bulb Replacement Notes 15-20 Thermostatic Fan Switch Inspection 15-22 Precautions 15-6 Water Temperature Sensor inspection 15-22 Electrical Wiring 15-7 Lighting System 15-23 Inspection 15-7 KLX250D Wiring Diagram 15-8...
  • Page 216: Exploded View

    15-2 ELECTRICAL SYSTEM Exploded View KLX250D/E KLX250D KLX250E KLX250E KLX250D SS: Apply sillicone sealant 1. Regulator/Rectifier 14 N-m (1.4 kg-m, 10 ft-lb) 2. Condenser 120 N-m (12.0 kg-m, 87 H-lb) 3. Ignition Coil 5.9 N-m (0.6 kg-m, 52 in-lb) 4. IC Igniter 2.5 N-m (0.25 kg-m, 22 in-lb)
  • Page 217 ELECTRICAL SYSTEM 15-3 KLX250D KLX250D/E KLX250D...
  • Page 218 15-4 ELECTRICAL SYSTEM KLX250D 1. Front Brake Switch 2. Engine Stop Switch 3. Lighting Switch 4. Side Stand Switch 5. Rear Brake Switch 6. Diode 7. Turn Signal Light Relay 8. head Light Relay...
  • Page 219: Specifications

    Special Tools - Hand Tester: 57001-983 Spark Plug Wrench, Hex 18: 57001-1024 Rotor Holder: 57001-1184 Flywheel Puller, M30 x 1.5: 57001-1191 Rotor Puller, M16/M18/M20/M22 x 1.5: 57001-1216 Timing Light: 57001-1241 Coil Tester: 57001-1242 Flywheel Holder: 57001-1313 Sealant- Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 220: Precautions

    15-6 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. OThe electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 221: Electrical Wiring

    ELECTRICAL SYSTEM 15-7 Electrical Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. * l f any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  • Page 222 Color Code B l a c k B l u e Brown C h o c o l a t e Dark Green Green Gray L i g h t Blue L i g h t Green Orange P i n k P u r p l e W h i t e Ye I low...
  • Page 223: Klx250e Wiring Diagram (european Model)

    KLX250E Wiring Diagram (European model)
  • Page 224 ELECTRICAL SYSTEM 15-9...
  • Page 225: Flywheel Magneto

    ELECTRICAL SYSTEM 15-11 Flywheel Magneto Stator Removal • Remove the magneto cover. • Remove the holding plate [A](KLX250E). • Unfit the grommet [B] holding the stator coil and pick up coil leads out of the notch of cover. • Unscrew the mounting bolts [C], and take off the stator [D]. Stator Installation Notes •...
  • Page 226: Charging System

    15-12 ELECTRICAL SYSTEM Charging System Regulator Inspection •Turn off the ignition switch. • Remove the left side cover. • Remove the regulator [A]. • Set the hand tester x 1 kQ range, and connect it to the terminals in the regulator connector, and check the resistance in both directions of each diode following the table.
  • Page 227: Ignition System

    ELECTRICAL SYSTEM 15-13 Ignition System Safety Instructions: AWARNING The Ignition system produces extremely high voltage. Do not touch the spark plug, high tension coil, or spark plug lead while the engine is running, or you should receive a severe electrical shock. CAUTION Do not disconnect electrical connections while the engine is running.
  • Page 228: Spark Plug Cleaning And Inspection

    15-14 ELECTRICAL SYSTEM • Remove the ignition coil. • Measure the primary winding resistance [A]. O Connect an ohmmeter between the coil terminals. OSet the meter to the x 1 Q range, and read the meter. • Measure the secondary winding resistance [B]. •...
  • Page 229: Cdi Unit Inspection

    Special Tool - Hand Tester: 57001-983 CAUTION Use only the Kawasaki Hand Tester for this test. A tester other than the Kawasaki Hand Tester may show different readings. Do not use a megger or a meter with a large capacity, or the CDI unit...
  • Page 230: Pickup Coil Inspection

    15-16 ELECTRICAL SYSTEM Pickup Coil Inspection • Remove: Side Covers Seat • Disconnect the pickup coil lead connector. •Set the hand tester to the x10D range, zero it, and connect it to the pickup coil lead terminals in the connector. * l f there is more resistance than the specified value, the coil has an open lead and must be replaced.
  • Page 231 ELECTRICAL SYSTEM 15-17 Diode Unit Check...
  • Page 232 15-18 ELECTRICAL SYSTEM KLX250E Headlight Circuit Wiring Diagram (Europe Model) Headlight Circuit Wiring Diagram (Australia Model) KLX250E...
  • Page 233 ELECTRICAL SYSTEM 15-19 Turn Signal Light Circuit W i r i n g Diagram KLX250E...
  • Page 234: Meter (klx250e)

    15-20 ELECTRICAL SYSTEM Meter (KLX250E) Removal • Remove the headlight unit. • Disconnect the meter lead connectors [A] • Disconnect the speedometer cable upper end [B]. • Unscrew the mounting nuts [A], and remove the meter unit [B]. CAUTION Place the meter or gauge so that the face is up. If a meter or gauge is left upside down or sideways for any length of time, it will malfunction.
  • Page 235 ELECTRICAL SYSTEM 15-21 Ignition Circuit (KLX250D) 1. Engine Stop Switch 2. Ignition Coil 3.CDI Unit 4. Magneto 5. Pickup Coil (KLX250E) Starter Lockout Switch 5. Ignition Coil 1. Ignition Switch 10. I.C.Igniter 6. Neutral Indicator Light 2. Engine Stop Switch 11.
  • Page 236: Thermostatic Fan Switch Inspection

    15-22 ELECTRICAL SYSTEM Thermostatic Fan Switch Inspection • Remove the fan switch from the radiator (see Thermostatic Fan Switch Removal in the Cooling System chapter). • Suspend the switch in a container of water so that the temperature-sensing projection and threaded portion are submerged. •...
  • Page 237: Lighting System

    ELECTRICAL SYSTEM 15-23 Lighting System The KLX250E Australia model has a headlight relay. In this model, the headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 238: Note

    15-24 ELECTRICAL SYSTEM Headlight Lens Removal I Installation Note • Be careful not to overtighten the lens mounting bolts [A]. Turn Signal Inspection (KLX250E) • Remove the turn signal relay. • Connect one 12 V battery and turn signal lights as indicated in the figure, and count how many times the lights flash for one minute.
  • Page 239: Radiator Fan (klx250e)

    E L E C T R I C A L S Y S T E M 15-25 Radiator Fan (KLX250E) Radiator Fan Removal AWARNING Never touch the radiator fan until the ignition switch is turned off. Touching the fan before the ignition switch is turned off could cause injury from the fan blades.
  • Page 240 15-26 ELECTRICAL SYSTEM • Connect the hand tester [A] and 12 V battery [B] to the fan relay [C] as shown. * If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: x l Q Criteria: When battery is connected - >...
  • Page 241: Coolant Temperature Warning System (klx250e)

    ELECTRICAL SYSTEM 15-27 Coolant Temperature Warning System (KLX250E) When the ignition switch is turned on with the transmission in neutral, the warning light flashes regardless of coolant temperature. This is to show if the light bulb has burned out. If the water temperature is high, the warning light flashes even if the transmission is in gears until water temperature falls.
  • Page 242 15-28 ELECTRICAL SYSTEM Coolant Temperature Warning Circuit 1. Ignition Switch 4. Interlock Diode Unit 7. Regulator/Rectifier 2. Coolant Temperature Warning Light 5. Diode 8. Magneto 3. Coolant Temperature Sensor 6. Neutral Switch...
  • Page 243: Switches (klx250e)

    ELECTRICAL SYSTEM 15-29 Switches (KLX250E) Brake Light Timing Inspection • T u r n the ignition switch to the ON position. • Start the engine. • Check the operaiton of the rear brake light switch by depressing the brake pedal. •*-|f the light does not go on as specified, adjust the brake light timing.
  • Page 244 APPENDIX 16-1 Appendix Table of Contents Additional Considerations for Racing (KLX250E) 16-2 Carburetor. 16-2 Spark Plug: 16-2 Spark Plug Inspection 16-3 Troubleshooting Guide 16-4 Engine Doesn't Start, Starting Difficulty: 16-4 Poor Running at Low Speed: 16-4 Poor Running or No Power at High Speed: 16-5 Overheating: 16-5...
  • Page 245: Additional Considerations For Racing (klx250e)

    • Y o u are entirely responsible for the use of your motorcycle under abnormal conditions such as racing, and Kawasaki shall not be liable for any damages which might arise from such use. • Kawasaki's Limited Motorcycle Warranty and Limited Emission Control Systems Warranty specifically exclude motorcycles which are used in competition or related uses.
  • Page 246: Spark Plug Inspection

    APPENDIX 16-3 When a plug of the correct heat range is being usea, the electrodes will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself. This temperature is about 400 ~ 800°C (750 ~ 1450°F) and can be judged by noting the condition and color of the ceramic insulator around the center electrode.
  • Page 247: Troubleshooting Guide

    16-4 APPENDIX Troubleshooting Guide Cylinder head gasket damaged NOTE Cylinder head warped O This is not an exhaustive list, giving every possible Valve spring broken or weak cause for each problem listed. It is meant simply as a Valve not seating properly (valve bent, worn, or rough guide to assist the troubleshooting for some of carbon accumulation on the seating surface) the more common difficulties.
  • Page 248: Poor Running Or No Power At High Speed

    APPENDIX 16-5 Brakes dragging Compression release cam (K.A.C.R.) sticks open Clutch slipping (Engine stalls when moving off) Other: Overheating CDI unit trouble Engine oil level too high Engine oil viscosity too high Carburetor vacuum piston doesn't slide smoothly Balancer mechanism malfunctioning Engine oil viscosity too high Drive train trouble Drive train trouble...
  • Page 249: Gear Shifting Faulty

    16-6 APPENDIX Friction plate worn or warped Piston ring worn, broken, or stuck Steel plate worn or warped Piston seizure, damage Clutch spring broken or weak Cylinder head gasket leaking Clutch release mechanism trouble Exhaust pipe leaking at cylinder head connection Clutch hub or housing unevenly worn Crankshaft runout excessive Clutch not disengaging properly:...
  • Page 250: Handling And/or Stability Unsatisfactory

    APPENDIX 16-7 Brake fluid leakage Black smoke: Disc warped Air cleaner clogged Main jet too large or fallen off Contaminated pad Starter plunger stuck open Brake fluid deteriorated Primary or secondary cup damaged master Fuel level in carburetor float bowl too high cylinder Brown smoke: Master cylinder scratched inside...
  • Page 251: Nut, Bolt, And Fastener Tightness

    16-8 APPENDIX Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition. NOTE OFor the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 252: General Lubrication

    APPENDIX 16-9 General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below w i t h indicated lubricant in accord- ance with the Periodic Maintenance Chart.
  • Page 253: Unit Conversion Table

    1 6 - 1 0 A P P E N D I X Unit Conversion Table Units of Length: P r e f i x e s f o r Units: 0.6214 mile Power Prefix Symbol 3.281 0.03937 x 1 000 000 mega kilo x 1 000...
  • Page 254 SUPPLEMENT FOR 1994 MODEL 17-1 Supplement -1994 Model This "Supplement - 1994 Model" chapter is designed to be used in conjunction with the front part of this manual (up to 19-2). The maintenance and repair procedures described in this chapter are only those that are unique to the 1994 KLX250G-1 motorcycle.
  • Page 255: General Information

    17-2 SUPPLEMENT FOR 1994 MODEL General Information Model Identification KLX250-G1 KLX250-G2...
  • Page 256: General Specifications

    SUPPLEMENT FOR 1994 MODEL 17-3 General Specifications KLX250-G1,G2 Items Dimensions: 2170 mm, (W) 2220 mm Overall length 870 mm Overall width Overall height 1210 mm 1440 mm Wheelbase 300 mm Road clearance Seat height 890 mm 120 kg Dry weight 62 kg Curb weight: Front...
  • Page 257 17-4 SUPPLEMEMT FOR 1994 MODEL Items KLX250-G1, G2 Drive Train: Primary reduction system: Type Gear Reduction ratio 2.863 (63/22) Clutch type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear ratios: 3.000 (30/10) 2.000 (30/15) 1.500 (27/18) 1.250 (25/20) 1.050 (21/20) 0.904 (19/21) Final drive system:...
  • Page 258 S U P P L E M E N T FOR 1994 M O D E L 1 7 - 5 Periodic Maintenance Chart - KLX250G The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
  • Page 259 17-6 SUPPLEMENT FOR 1994 MODEL (t): For higher odometer readings, repeat at the frequency interval established here. (*): Replace, add, adjust, clean, or torque if necessary. (CA) : California Model (US) : U.S. Model...
  • Page 260: Technical Information (maintenance Free Battery)

    SUPPLEMENT FOR 1994 MODEL 17-7 Technical Information Maintenance Free Battery A maintenance free battery is installed in this model. The maintenance free battery is a sealed type, and so cannot be performed the electrolyte level check and toppinq-up. (I) Construction (II) Main Features 1) Maintenance free It is not necessary to check the electrolyte level and top-off the electrolyte.
  • Page 261 17-8 SUPPLEMENT FOR 1994 MODEL A maintenance free battery, however, is so designed that, when it is overcharged, even if the positive plate is fully charged, the negative plate remains not fully turned to spongy lead. Therefore, even when the positive plate is overcharged generating oxygen gas, the negative plate is no fully charged, hence generating no hydrogen gas.
  • Page 262 SUPPLEMENT FOR 1994 M O D E L 17-9 NOTE • Now pull the container gently out of the battery. • Let the battery sit for 20 minutes. During this time, the Off no air bubbles are coming up from a filler port, tap electrolyte permeates the special separators and the gas the bottom of the bottle two or three times.
  • Page 263 17-10 SUPPLEMENT FOR 1994 MODEL (VI) Precautions No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the sealing plug to add water is very dangerous. Never do that. Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged.
  • Page 264: Fuel System

    SUPPLEMENT FOR 1994 M O D E L 17-11 Fuel System Specifications KLX250G Item Standard 2 ~ 3 mm Throttle Grip Free Play Carburetor KEIHIN, CVK34 Make, type 1 1/2 (W) 1 1/4 Pilot screw (turns o ut) Service fuel level 1.5mm above ~ 0.5mm below the float bowl mating surface Float height 17.0 ±...
  • Page 265: Suspension

    17-12 SUPPLEMENT FOR 1994 MODEL Suspension Specifications Standard Item Front Fork (per one un t ) : Fork inner tube diameter 43 mm Air pressure Atmospheric pressure (Non-adjustable) Compression damper setting 14th click from the first click of the fully clockwise position Fork oil viscosity KAYABA 01 or SAE5W...
  • Page 266: Electrical System

    SUPPLEMENT FOR 1994 MODEL 17-13 Electrical System Specifications Item Standard Service Limit Battery: Type MF (Maintenance Free) Battery Capacity 12V 6 Ah Voltage 12.6 V or more Charging System: Alternator type Three-phase AC Charging voltage 14 ~ 1 5 V (regulator/rectifier output voltage) Alternator output voltage more than 34 V @4000 r/min (rpm)
  • Page 267 17-14 SUPPLEMENT FOR 1994 MODEL...
  • Page 268 K L X 2 5 0 G W i r i n g D i a g r a m...
  • Page 269 SUPPLEMENT FOR 1994 MODEL 17-15...
  • Page 270: Battery

    SUPPLEMENT FOR 1994 MODEL 17-17 Battery Charging Condition Inspection Battery charging condition checked measuring battery terminal voltage. • Remove: Seat IC Igniter Diode • Disconnect the battery terminal leads. CAUTION Be sure to disconnect the negative terminal lead first. • Measure the battery terminal voltage. N O T E 1.
  • Page 271 17-18 SUPPLEMENT FOR 1994 MODEL Battery Standard Charge Time Chart • Determine battery condition after refreshing charge. O Determine the condition of the battery 30 minutes after (0.7 A x 5 ~ 10 h Regular Current Charge) - For Reference completion of the charge by measuring the terminal voltage according to the table below.
  • Page 272: Headlight Circuit Wiring Diagram

    SUPPLEMENT FOR 1994 MODEL 17-19 Ignition System Refer to pp. 15-23, noting the following. Headlight Circuit Wiring Diagram KLX250G Turn Signal Light Circuit W i r i n g Diagram KLX250G...
  • Page 273: Radiator Fan Circuit

    17-20 SUPPLEMENT FOR 1994 MODEL Refer to pp. 15-25, noting the following. Radiator Fan Circuit 1. Radiator Fan Motor 5. Fuse 10 A 2. Fan Switch 6. Battery 3. Radiator 7. Main Fuse 20 A 4. Fan Relay...
  • Page 274: Coolant Temperature Warning System

    SUPPLEMENT FOR 1994 M O D E L 17-21 Coolant Temperature Warning System Refer to pp. 15-17, noting the following Coolant Temperature Warning Circuit 5. Diode 1. Ignition Switch 2. Coolant Temperature Warning Light 6. Neutral Switch 3. Coolant Temperature Sensor 7.
  • Page 275 MEMO...
  • Page 276 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 Department/Consumer Products Group/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 277 LIST OF ABBREVIATIONS ampere(s) pounds(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC newton (s) after top dead center BBDC before bottom dead center pascal (s) horsepower bottom dead center BTDC before top dead center pound(s) per square inch "C degree(s) Celsius revolution...
  • Page 278 • Be alert for problems and non-scheduled mainte- instructions or procedures w h i c h , if not nance. strictly observed, could result in damage to • Use proper tools and genuine Kawasaki Motorcy- or destruction of equipment. cle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcy- cles are introduced by the Special Tool Manual.
  • Page 279 NOTE This note symbol indicates points of partic- ular interest for more efficient and convenient operation. 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.
  • Page 280 Table of Contents General Information Model Identification General Specifications Periodic Maintenance Chart Torque and Locking Agent Cables, Wires and Hoses Piping Diagram Fuel System Specifications Engine Top End Specifications Final Drive Specifications Brakes Specifications Suspension Exploded View Specifications Electrical System KLX300A Wiring Diagram...
  • Page 281: General Information

    General Information Model Identification KLX300-A2...
  • Page 282: General Specifications

    General Specifications KLX300-A2 Items Dimensions: Overall length 2 115 mm Overall width 910 mm Overall height 1 220mm Wheelbase 1 435 mm Road clearance 320 mm Seat height 925 mm Dry weight 105 kg 54 kg Curb weight: Front Rear 60 kg 9.8 L Fuel tank capacity...
  • Page 283 KLX300-A2 Items Drive Train: Primary reduction system: Gear Type Reduction ratio 2.863(62/22) Clutch type Wet, multi disc Transmission: 6-speed, constant mesh, return shift Type 3.000 (30/10) Gear ratios: 2.000 (30/15) 1.500(27/18) 1.250 (25/20) 0.050 (21 /20) 0.904(19/21) Final drive system: Type Chain drive Reduction ratio...
  • Page 284 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. ENGINE Clutch -- adjust Clutch and friction plates -- check* Throttle cables -- adjust Spark plug -- clean, check* Valve clearance -- check* Air cleaner element -- clean Air cleaner element -- replace...
  • Page 285 Steering stem bearing -- grease Rear sprocket -- check* Wheel bearing -- lubricate* Swingarm and uni-trak linkage pivots - - grease Swingarm and uni-trak linkage pivots - - check* Rear shock oil -- change ENGINE and CHASSIS Fuel system -- clean Fuel hose -- replace Nuts, bolts, fasteners -- tighten* General lubrication -- perform...
  • Page 286 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasekt. Letters used in the "Remarks" column mean: : Apply a non-permanent locking agent to the threads. LG : Apply liquid gasket to the threads.
  • Page 287 Torque Remarks Remarks Fastener Fastener kg-m ft-lb Engine Lubrication System: 11.0 Engine Oil Drain Plug 11.0 Oil Pressure Relief Valve 87 in-lb Oil Pipe Banjo Bolts 14.5 0.55 48 in-lb Oil Pump Mounting Screws Engine Removal/Installation: Swing Arm Pivot Shaft Nut Engine Mounting Nuts Cylinder Head Bracket Bolts Crankshaft/Transmission:...
  • Page 288 Fastener Fastener Torque Remarks Remarks kg-m ft-lb Front Fork Upper Clamp Bolts 14.5 Front Fork Lower Clamp Bolts 18.0 Steering Stem Locknut Hand-Tighten Hand-Tighten Hand Tighten [about 3.9] [about 0.4] [about 35 in-lb] Electrical System: Spark Plug Magneto Flywheel Bolt Stator Coil Mounting Bolts 52 in-lb Pickup Coil Mounting Screws...
  • Page 289: Cables, Wires And Hoses Piping Diagram

    Cables, Wires and Hoses Piping Diagram 1. Throttle Cable (decelerate side) L-shaped Joint Direction of Travel Be sure to install and fix the L-shaped joint of the decelerate side, facing 45 degrees to the direction of travel.
  • Page 290: Fuel System

    Fuel System Specifications Item Standard Throttle Grips and Cables 2 ~ 3 mm Throttle Grip Free Play Carburetor KEIHIN, C V K 3 4 Make, type Pilot screw (turns out) 2 1/2 1.5 mm above ~ 0.5 mm below the float bowl mating surface Service fuel level 17 ±...
  • Page 291: Engine Top End

    Engine Top End Specifications Item Standard Service Limit Cylinder, Piston: Cylinder inside diameter 78.000 ~ 78.012 mm 78.07 mm Piston diameter 77.950 ~ 77.965 mm 77.80 mm Piston/cylinder clearance 0.035 ~ 0.062 mm Piston ring/groove clearance 0.035 ~ 0.062 mm 0.03 ~ 0.07 mm 0.17 mm Second...
  • Page 292: Final Drive

    Final Drive Specifications Item Standard Service Limit Drive Chain: Standard Chain Make DAI DO D.I.D.520VL-2, Endless Type Link Chain slack 50 ~ 60 mm 5 0 - 6 5 mm 3 1 7 . 5 - 318.2 mm 20-link length 323 mm Sprockets 60.98 - 6 1 .
  • Page 293: Brakes

    Brakes Specifications Standard Service Limit Item Brake Lever, Brake Pedal Brake lever free play Adjustbale (to suit rider) Pedal free play Non-adjustable Brake Fluid: Grade 315AA, D.0.T.3 or 418AA, D.O.T.4 Brand (recommended) Shown below Brake Pads: Lining thickness Front 3.8 mm 1 mm Rear 6.4 mm...
  • Page 294: Suspension

    Suspension Exploded View Upside Down Type : Apply Grease : Apply a non-permanent Gasket : Apply Molybdenum Disulfide Grease LG : Apply Liquid Gasket T1 : 9.8 N-m (1.0 kg-m, 87 in-lb) T2 :13 N-m (1.3 kg-m, 9.5 ft-lb) T3 : 20 N-m (2.0 kg-m, 14.5 ft-lb) T4 : 23 N-m (2.3 kg-m, 16.5 ft-lb) T5 : 29 N-m (3.0 kg-m, 22 ft-lb) T6 : 39 N-m (4.0 kg-m, 29 ft-lb)
  • Page 296: Specifications

    Specifications Item Standard Front Fork (per one unit): Fork inner tube diameter 43 mm Air Pressure Atmospheric pressure (Non-adjustable) 12th click from the first click of the fully clockwised position Compression damper setting KAYABA 01 or SAE5W Fork oil viscosity Fork oil capacity 540 ±...
  • Page 297 Color Code B l a c k B l u e Brown C h o c o l a t e Dark Green Green Gray L i g h t B l u e L i g h t Green o r a n g e P ink P u r p l e...
  • Page 298 E M I S S I O N C O N T R O L I N F O R M A T I O N To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
  • Page 299 NOTE o The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary or rendering inoperative of devices or elements of design in order to perform maintenance. 2.

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