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Table of Contents

   Also See for Kawasaki KX250F

   Summary of Contents for Kawasaki KX250F

  • Page 2 GENERAL INFORMATION Quick Reference Guide MAINTENANCE AND ADJUSTMENT This Quick Reference Guide will assist you in finding the information you’re looking for. TROUBLESHOOTING GUIDE TUNING STORAGE A Table of Contents is included after the Foreword.
  • Page 3 IMPORTANT INFORMATION • This vehicle is designed for the operator only, no passengers. • This vehicle is a competition model only and was not manufactured for use on public streets, roads or highways. • The use of this vehicle should be limited to participation in sanctioned competition events upon a closed course.
  • Page 4 Whenever you see the symbols shown below, IMPORTANT NOTICE heed their instructions! Always follow safe operat- THIS VEHICLE IS A COMPETITION MODEL ing and maintenance practices. ONLY MANUFACTURED FOR, NOR SHOULD IT BE USED ON, PUB- DANGER LIC STREETS, ROADS, OR HIGHWAYS. THE DANGER indicates a hazardous situation USE OF THIS VEHICLE SHOULD BE LIMITED which, if not avoided, will result in death or...
  • Page 5 Motorcycle Noise Emission Control Information This motorcycle is designed for closed course competition use only. It does not conform to U.S. EPA motorcycle noise standards. NOTICE Off-road motorcycling is a wonderful sport, and we hope you will enjoy it to the fullest. How- ever, if improperly conducted, this sport has the potential to cause environmental problems as well as conflicts with other people.
  • Page 6 WARNING The engine exhaust from this product con- tains chemicals known to the State of Cali- fornia to cause cancer, birth defects or other reproductive harm.
  • Page 7 Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight, high-performance machine with superb handling and stability for racing and sporting use. Your new KX is a highly tuned competition machine for participation in racing events. As with any mechan- ical device, proper care and maintenance are important for trouble-free operation and top performance.
  • Page 8: Table Of Contents

    TABLE OF CONTENTS SPECIFICATIONS..........Exhaust System ..........GENERAL INFORMATION......Drive Chain............ Location of Labels ......... Handlebars ............ Location of Parts ........... Brakes ............Side Stand............. Steering ............100 Fuel ............... Front Suspension .......... 103 ® Fuel Requirement:........Rear Suspension (UNI-TRAK ).....
  • Page 9: Specifications

    SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length 2 170 mm (85.43 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 270 mm (50.00 in.) Wheelbase 1 475 mm (58.07 in.) Road Clearance 330 mm (13.0 in.) Curb Mass 106.0 kg (233.7 lb) Fuel Tank Capacity 6.1 L (1.6 US gal) ENGINE...
  • Page 10 SPECIFICATIONS TRANSMISSION Transmission Type 5-speed, constant mesh, return shift Clutch Type Wet, multi disc Driving System Chain drive Gear Ratio: 2.142 (30/14) 1.750 (28/16) 1.444 (26/18) 1.235 (21/17) 1.045 (23/22) Primary Reduction Ratio 3.350 (67/20) Final Reduction Ratio 3.846 (50/13) Overall Drive Ratio 13.470 @Top gear Engine Oil:...
  • Page 11 Front Suspension Travel 315 mm (12.4 in.) Rear Wheel Travel 310 mm (12.2 in.) Front Fork Oil: Type Kawasaki Fork Oil SS19 Amount (Left Front Fork): Cylinder Unit 330 mL (11.2 US oz.) Outer Tube 300 mL (10.1 US oz.) Amount (Right Front Fork) 223 mL (7.54 US oz.)
  • Page 12: General Information

    If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct po- sition. NOTE 1.
  • Page 13 GENERAL INFORMATION 2. Brake Fluid (Rear) 3. Radiator Cap Danger 4. Rear Shock Absorber Warning...
  • Page 14 GENERAL INFORMATION 5. Noise Emission Control Information 6. Important Information 7. Disclaimer of Warranty...
  • Page 15 GENERAL INFORMATION...
  • Page 16 GENERAL INFORMATION...
  • Page 17: Location Of Parts

    GENERAL INFORMATION Location of Parts 1. Clutch Lever 4. Orange Launch Control 6. Front Brake Fluid Reservoir 2. Engine Stop Button Mode/FI Warning Indicator 7. Front Brake Lever 3. Launch Control Mode Light 8. Throttle Grip Button 5. Fuel Tank Cap...
  • Page 18 GENERAL INFORMATION 1. Front Fork 6. Upstream Injector 11. Shift Pedal 2. Radiator 7. Seat 12. Rear Shock Absorber 3. Fuel Tank 8. Air Cleaner Element 13. Swingarm 4. Throttle Body Assy 9. Brake Disc 14. Drive Chain 5. Downstream Injector 10.
  • Page 19 GENERAL INFORMATION ® 1. Muffler 6. Uni-Trak Tie-Rod and Rocker Arm 2. Rear Brake Fluid Reservoir 7. Oil Level Inspection Window 3. Rear Shock Absorber Gas Reservoir 8. Rear Brake Pedal 4. Kick Pedal 9. Exhaust Pipe 5. DFI Setting Data Selection Connector...
  • Page 20: Side Stand

    GENERAL INFORMATION NOTE Side Stand ○ Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures. To install the side stand, insert its flat end into the rear axle as shown in the figure. A. Side Stand B.
  • Page 21: Fuel

    Avoid filling the tank in the rain or where heavy dust Fuel is blowing so that the fuel does not get contaminated. This Kawasaki KX has a 4-stroke engine that re- quires a gasoline. The capacity of the fuel tank is 6.1 L (1.6 US gal).
  • Page 22: Fuel Requirement

    GENERAL INFORMATION NOTICE WARNING Gasoline is extremely flammable and can be If engine “knocking” or “pinging” occurs, explosive under certain conditions. Always use a different brand of gasoline of a higher stop the engine and do not smoke. Make octane rating. sure the area is well-ventilated and free from If this condition is allowed to continue it can any source of flame or sparks;...
  • Page 23 Other oxygenates approved for use in unleaded blends during refueling. gasoline include TAME (up to 16.7%) and ETBE When not operating your Kawasaki for 30 (up to 17.2%). Fuel containing these oxygenates to 60 days, mix a fuel stabilizer (such as can also be used in your Kawasaki.
  • Page 24: Kick Pedal

    GENERAL INFORMATION Kick Pedal Starting the Engine • This motorcycle is equipped with a primary kick Shift the transmission into neutral. starting system. When the clutch lever is pulled, the WARNING motorcycle can be started with the transmission in any gear. Riding with the side stand can cause a crash resulting in injury.
  • Page 25 GENERAL INFORMATION When engine is cold - When engine is already warm or restarts - • • Pull out the idle adjusting screw/choke knob. Kick the engine over, leaving the throttle closed without using the idle adjusting screw/choke knob. NOTE ○...
  • Page 26: Launch Control Mode

    GENERAL INFORMATION • When shifting into 3rd, the system is deactivated Launch Control Mode automatically. The launch control mode can be used to adjust ig- nition timing to help riders get better starts on slip- pery terrain. The system’s effectiveness is dependent on rider skill, technique and terrain conditions.
  • Page 27: Dfi Setting Data Selection

    GENERAL INFORMATION NOTE DFI Setting Data Selection ○ If the connector is changed while the engine is running, the DFI setting does not change. ○ Three DFI settings are available to suit various The ECU is set to the standard track condition track conditions.
  • Page 28: Shifting Gears

    GENERAL INFORMATION Shifting Gears This motorcycle is equipped with a 5-speed “return shift” transmission. The neutral is located halfway between 1st and 2nd gear. “Return shift” means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected.
  • Page 29: Stopping The Motorcycle

    GENERAL INFORMATION Stopping the Motorcycle Stopping the Engine • For maximum deceleration, close the throttle and Shift the transmission into the neutral position. • apply both front and rear brakes. Pull in the clutch Close the throttle completely and push the engine lever as the motorcycle comes to a stop.
  • Page 30: Break-in

    GENERAL INFORMATION Stop and let the engine cool completely. Be Break-In sure to fully check the tightness of nuts and bolts, oil leakage, and any irregularities, espe- A brief break-in procedure must be carried out to cially, each cable elongation, brake play, chain obtain the proper operating clearances in the engine slack and spoke tightness.
  • Page 31: Daily Pre-ride Checks

    GENERAL INFORMATION Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and take the action required to return the motorcycle to a safe operating condition.
  • Page 32 GENERAL INFORMATION Properly installed Engine Sprocket ......No wear or damage Frame Tires ..........Overall condition good No wear or damage Pressure correct Air valve cap installed Spokes ........No looseness Drive Chain ......... Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ....
  • Page 33: After-race Checks

    GENERAL INFORMATION Carry out the general lubrication and make neces- After-Race Checks sary adjustments. After racing, first clean the motorcycle, then in- spect the entire motorcycle with special attention to the air cleaner, brakes, etc.
  • Page 34: Maintenance And Adjustment

    Periodic Maintenance Chart to keep the motorcycle in good running condition. †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. 1. Periodic Inspection (Engine Related Item)
  • Page 35 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) • – Kick pedal and shift pedal - clean •...
  • Page 36 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) • Brake - adjust † •...
  • Page 37 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 Every 6 Every 12 race (or races (or races (or races (or required Page OPERATION 2.5 hours) 7.5 hours) 15 hours) 30 hours) Swingarm and UNI-TRAK linkage • – pivots - inspect † Swingarm and UNI-TRAK linkage •...
  • Page 38 MAINTENANCE AND ADJUSTMENT 3. Periodic Replacement (Engine and Chassis Related Item) FREQUENCY After each Every 3 Every 6 Every 12 race (or 2.5 races (or 7.5 races (or 15 races (or Page OPERATION hours) hours) hours) 30 hours) • Engine oil - change •...
  • Page 39: Engine Oil

    MAINTENANCE AND ADJUSTMENT NOTICE Engine Oil Racing the engine before the oil reaches ev- ery part can cause engine seizure. In order for the engine, transmission and clutch to function properly, maintain the engine oil at the Oil Level Inspection proper level, and change the oil and oil filter period- •...
  • Page 40 MAINTENANCE AND ADJUSTMENT • NOTE Warm up the engine thoroughly so that the oil will ○ pick up any sediment and drain easily. If no oil appears in the oil level inspection window, • Stop the engine, and place a container beneath it. tip the motorcycle slightly to the right until oil is •...
  • Page 41 MAINTENANCE AND ADJUSTMENT • • When the oil filter is replaced, remove the oil fil- Replace the oil filter element with a new one. • ter cap bolts and take off the cap with O-ring and Apply grease to the grommet. •...
  • Page 42 Semi-Synthetic Oil*” 10W-40 or “Kawasaki Performance 4-Stroke Motorcycle Oil*” 10W-40 A. Spring *Kawasaki Performance Oils and Lubricants have B. O-ring been specifically engineered for your vehicle. Con- C. Oil Filter Cap sistent use of these products meets or exceeds ser-...
  • Page 43 MAINTENANCE AND ADJUSTMENT NOTE The oil viscosity may need to be changed to ac- ○ commodate atmospheric conditions in your riding If unavailable, use equivalent engine oil in accor- area. dance with the following table. Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-30, 10W-40, 10W-50...
  • Page 44: Cooling System

    MAINTENANCE AND ADJUSTMENT WARNING Cooling System The cooling system can get extremely hot during normal operation and cause serious Water Hoses burns. Do not touch the radiator when it is Check the water hoses for cracks or deterioration, hot, nor open the radiator cap. Hot coolant and the connections for looseness in accordance inside will cause severe burns.
  • Page 45 MAINTENANCE AND ADJUSTMENT • Situate the motorcycle perpendicular to the ground until the radiator cap is level to the ground, so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator. • Remove the radiator cap in two steps. •...
  • Page 46 MAINTENANCE AND ADJUSTMENT • Install the radiator cap. • Temporarily tighten the radiator shroud bolts fol- lowing the tightening sequence. A. Coolant Drain Bolt NOTICE • Tighten the radiator shroud bolts securely. Immediately wash away any coolant that spills on the frame, engine, or wheel. Coolant Change The coolant should be changed to ensure long en- gine life, if necessary.
  • Page 47 MAINTENANCE AND ADJUSTMENT • NOTE If the coolant is brown, iron or steel parts are rust- ○ ing and the system must be flushed. Pour in the coolant slowly so that it can expel the • Check the cooling system for damage, loose con- air from the engine and radiator.
  • Page 48: Spark Plug

    MAINTENANCE AND ADJUSTMENT If the plug is oily or has carbon built up on it, clean Spark Plug it. The plug may also be cleaned using a high flash -point solvent and a nonmetal brush (nylon etc.). If The spark plug should be taken out periodically for the spark plug electrodes are corroded, or damaged, inspection and regapping.
  • Page 49 MAINTENANCE AND ADJUSTMENT • Remove the fuel tank mounting bolt and band. A. Bolts B. Radiator Shroud A. Fuel Tank Mounting Bolt B. Band...
  • Page 50 MAINTENANCE AND ADJUSTMENT • WARNING Be sure to place a piece of cloth around the fuel hose joint. Fuel is flammable and explosive under cer- • Wipe off the dirt of the surface around the connec- tain conditions and can cause severe burns. tion using a cloth or a soft brush.
  • Page 51 MAINTENANCE AND ADJUSTMENT • • Turn the driver to disconnect the joint lock. Disconnect the fuel pump lead connector. • • Disconnect the fuel hose joint from the outlet pipe. Remove the fuel tank. A. Fuel Pump Lead Connector A. Turn B.
  • Page 52 MAINTENANCE AND ADJUSTMENT • Clean the cylinder head cover around the spark Tightening Torque plug cap hole before removing the spark plug. Spark Plug: • Pull the spark plug cap off the plug before remov- 13 N·m (1.3 kgf·m, 115 in·lb) ing the spark plug.
  • Page 53 MAINTENANCE AND ADJUSTMENT • • Make sure that the dampers are in place on the Insert the fuel hose joint straight onto the fuel out- frame and are not damaged. If the dampers are let pipe until the hose joint clicks. •...
  • Page 54 MAINTENANCE AND ADJUSTMENT • • Push and pull the fuel hose joint back and forth Hook the band to the fuel tank. • more than two times, and make sure it is locked Tighten the fuel tank mounting bolt. • and does not come off.
  • Page 55: Air Cleaner

    MAINTENANCE AND ADJUSTMENT Air Cleaner A clogged air cleaner restricts the air intake, in- creases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air intake system, which includes the air filter and air duct to the throttle body assy, and the duct clamps and throttle body assy, before each race or practice session.
  • Page 56 MAINTENANCE AND ADJUSTMENT • Element Removal and Inspection Open the both side covers slightly outward and • Remove the bolt on the right and left sides. slide the seat rearward. A. Side Covers A. Bolt B. Seat...
  • Page 57 MAINTENANCE AND ADJUSTMENT • NOTICE Remove the wing bolt, and take out the air cleaner element. Do not twist or wring the element, as it gets easily torn or damaged. • Inspect the element. If it is dirty, clean it. Also check if the element is in good condition (no tears, hardening or shrinkage).
  • Page 58 MAINTENANCE AND ADJUSTMENT A. Air Cleaner Element B. Element Frame Element Cleaning and Installation • Clean the element in a bath of a high flash-point solvent or hot soapy water. Rinse the element with clear water to remove all traces of the cleaning solution.
  • Page 59 MAINTENANCE AND ADJUSTMENT • WARNING Remove the towel from the throttle body assy. • Install the element onto its frame, and coat the Gasoline and low flash-point solvents can element lip and lip seat with a thick layer of all be flammable and/or explosive and cause -purpose grease to assure a complete seal.
  • Page 60 MAINTENANCE AND ADJUSTMENT • • Install the air cleaner element so that its tab faces Insert the hooks of the seat under the flange collar upward and its projections align with the holes in and brackets. the housing. A. Hooks B.
  • Page 61: Throttle Cable

    MAINTENANCE AND ADJUSTMENT • Install the tabs of the side covers into the inside of Throttle Cable the seat, and tighten the bolts. Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart.
  • Page 62: Throttle Body Assy

    MAINTENANCE AND ADJUSTMENT Throttle Body Assy Idle Speed Adjustment • Thoroughly warm up the engine. • Turn the idle adjusting screw/choke knob to adjust the idle speed 2 000 ∼ 2 100 r/min (rpm) by using the engine revolution tester (The tester should be followed by the method described by the manufac- ture.).
  • Page 63 MAINTENANCE AND ADJUSTMENT Cleaning the Throttle Body Assy the idle speed. If so, the throttle cable may be im- • properly adjusted, incorrectly routed, or damaged. Remove the seat (see Air Cleaner section). • Be sure to correct any of these conditions before Remove the fuel tank (see Spark Plug section).
  • Page 64 MAINTENANCE AND ADJUSTMENT • • Loosen the muffler clamp bolt. Loosen the air cleaner duct clamp bolt. • • Remove the muffler mounting bolts, and pull out Disconnect the intake air temperature sensor con- the muffler body rearward. nector. A. Air Cleaner Duct Clamp Bolt A.
  • Page 65 MAINTENANCE AND ADJUSTMENT • • Disconnect the intake air pressure sensor con- Be sure to place a piece of cloth around the fuel nector, downstream injector connector and throt- hose joint. • tle sensor connector. Wipe off the dirt of the surface around the connec- tion using a cloth or a soft brush.
  • Page 66 MAINTENANCE AND ADJUSTMENT • • Turn the driver to disconnect the joint lock. Disconnect the upstream injector connector. • • Disconnect the fuel hose joint from the outlet pipe. Be sure to place a piece of cloth around the fuel hose joint.
  • Page 67 MAINTENANCE AND ADJUSTMENT • Loosen the throttle body assy holder clamp screw. • Pull the throttle body assy from the holder. A. Rear Frame Mounting Bolts B. Air Cleaner Housing A. Throttle Body Assy Holder Clamp Screw...
  • Page 68 MAINTENANCE AND ADJUSTMENT • • Remove the bolts, and take off the throttle pulley Loosen the decelerator cable bolt locknut, and cover. free the tip of cable lower end. • Loosen the accelerator cable bolt, and free the tip of cable lower end. A.
  • Page 69 MAINTENANCE AND ADJUSTMENT • WARNING After removing the throttle body assy, cover the throttle body assy holder and air cleaner duct with Operation with improperly adjusted, incor- a clean cloth to protect them from dirt. rectly routed, or damaged cables could re- •...
  • Page 70 MAINTENANCE AND ADJUSTMENT • Install the throttle body assy to the throttle body assy holder. Align the projection with the groove. • Check the throttle body assy is installed securely. A. Accelerator Cable B. Claw C. Decelerator Cable Bolt D. Decelerator Cable Bolt Locknut A.
  • Page 71 MAINTENANCE AND ADJUSTMENT • • Position the claw on the air cleaner duct clamp Tighten the rear frame mounting bolts to the spec- between the projections. ified torque. Tightening Torque Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 72 MAINTENANCE AND ADJUSTMENT NOTICE NOTE ○ If it comes off, reinstall the fuel hose joint. When installing the fuel hose joint, do not • apply strong force to the delivery pipe. The Fit the projection on the muffler body and hole on pipe made from resin could be damaged.
  • Page 73: Clutch

    MAINTENANCE AND ADJUSTMENT If the clutch lever free play cannot be adjusted at Clutch the clutch lever, make the adjustment further down the cable as follows. • Turn the adjuster in all the way. Clutch Lever Adjustment • Slide the dust cover back. Proper clutch lever free play is 8 ∼...
  • Page 74 MAINTENANCE AND ADJUSTMENT WARNING Too much cable play can prevent clutch dis- engagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creating enough cable play to prevent clutch disengagement.
  • Page 75 MAINTENANCE AND ADJUSTMENT • • Remove the clutch cover bolts. Remove the clutch cover and gasket. • Remove the clutch spring bolts, clutch pressure plate and springs. A. Bolts B. Clutch Cover A. Clutch Spring Bolts B. Clutch Pressure Plate...
  • Page 76 MAINTENANCE AND ADJUSTMENT • Remove the friction and steel plates. Steel Plate Thickness Measurement 1.5 ∼ 1.7 mm (0.059 ∼ 0.067 in.) Standard Service Limit 1.4 mm (0.055 in.) A. Friction Plate B. Steel Plate Friction Steel Plates Wear/Damage A. Thickness Inspection B.
  • Page 77 MAINTENANCE AND ADJUSTMENT Friction and Steel Plate Installation Friction and Steel Plate Warp • Install all parts in the reverse order of removal. 0.15 mm • Standard Install the friction plates and steel plates, alternat- (0.0059 in.) or less Friction Plate ing between the two;...
  • Page 78 MAINTENANCE AND ADJUSTMENT • Apply molybdenum disulfide grease to the steel cable bracket while pushing the release shaft lever ball and the contact area of the push rod holder. lightly forward. • Install the steel ball and the push rod holder. A.
  • Page 79 MAINTENANCE AND ADJUSTMENT Release Shaft Lever Position and Adjusting Washer Selection Position Judg- Washers Quan- Distance ment Thickness tity 49.2 ∼ 56.5 mm 1.5 mm Standard (1.94 ∼ 2.22 in.) (0.06 in.) More than 56.5 1.0 mm Too big mm (2.22 in.) (0.04 in.) Less than 49.2 1.0 mm...
  • Page 80: Valve Clearance

    MAINTENANCE AND ADJUSTMENT • Remove the fuel hose joint of the downstream in- Valve Clearance jector outlet pipe (see Throttle Body Assy section). • Remove the cylinder head cover bolts and cylinder Valve and valve seat wear decreases valve clear- head cover.
  • Page 81 MAINTENANCE AND ADJUSTMENT • • Remove the head cover gasket and spark plug Remove the two caps from the magneto cover. hole gasket. A. Timing Inspection Cap B. Flywheel Nut Cap A. Head Cover Gasket B. Spark Plug Hole Gasket...
  • Page 82 MAINTENANCE AND ADJUSTMENT • • Bring the piston to the Top Dead Center (TDC) of At this point, the timing marks on the camshaft its compression stroke to inspect the valve clear- sprockets must be almost aligned with the cylinder ance (the position at the end of the compression head upper surface.
  • Page 83 Standard Valve Clearance 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.) Exhaust 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) Intake • If the valve clearance is not within the specified A. Silicone Sealant range, adjust by an authorized Kawasaki dealer or...
  • Page 84 MAINTENANCE AND ADJUSTMENT • Replace the spark plug hole gasket with a new one, and apply grease to it. • Install the new gasket. A. Upper Chain Guide B. Cylinder Head Cover C. Head Cover Gasket A. Spark Plug Hole Gasket NOTICE •...
  • Page 85: Exhaust System

    MAINTENANCE AND ADJUSTMENT • Install the two caps to the magneto cover. Exhaust System Tightening Torque Timing Inspection Cap: The exhaust system, in particular the muffler body, 3.5 N·m (0.36 kgf·m, 31 in·lb) is designed to reduce exhaust noise and conduct the Flywheel Nut Cap: exhaust gases away from the rider while minimizing 3.5 N·m (0.36 kgf·m, 31 in·lb)
  • Page 86 MAINTENANCE AND ADJUSTMENT • • Remove the muffler cover bolts. Remove the muffler cover with the plastic mallet. • Remove the muffler mounting bolt (rear). A. Plastic Mallet B. Muffler Cover A. Muffler Cover Bolts B. Muffler Mounting Bolt (Rear)
  • Page 87 MAINTENANCE AND ADJUSTMENT • • Replace the silencer wool with a new one. Check that the exhaust port of the muffler cover • Remove the silicone sealant attaching on the muf- align with the muffler pipe. fler cover and muffler body. •...
  • Page 88 MAINTENANCE AND ADJUSTMENT A. Muffler Cover A. Muffler Clamp Bolt B. Muffler Body B. Muffler Mounting Bolt (Front) C. Muffler Cover Bolts C. Muffler Body D. Silicone Sealant NOTE ○ If the threaded holes of the muffler cover and muf- fler body do not align, remove the muffler clamp bolt and muffler mounting bolts.
  • Page 89: Drive Chain

    MAINTENANCE AND ADJUSTMENT • Insert the tabs of the side cover into the slots of Drive Chain the air cleaner housing, and tighten the bolts. For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated be- fore riding.
  • Page 90 MAINTENANCE AND ADJUSTMENT notch of the left chain adjuster should align with the same swingarm mark that the notch of the right chain adjuster aligns with. Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) A. Chain Slack •...
  • Page 91 MAINTENANCE AND ADJUSTMENT WARNING Misalignment of the wheel will result in ab- normal wear, and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and swingarm pivot.
  • Page 92 MAINTENANCE AND ADJUSTMENT overly tight chain, which can cause it to break. To prevent this, adjust the chain slack (measured ∼ between the chain and the swingarm) to 62 ∼ mm (2.4 2.7 in.). Chain Wear Inspection When the chain has reached its wear limit (i.e., when it has stretched by 1.7% of its original length), it is no longer safe for use and should be replaced.
  • Page 93 MAINTENANCE AND ADJUSTMENT ○ To minimize any chance of the master link coming apart, the master link clip must be installed with the closed end of the “U” pointing in the direction of chain rotation. A. Weight B. Tape Measure Drive Chain 20-Link Length 317.5 ∼...
  • Page 94 MAINTENANCE AND ADJUSTMENT Chain Guide Wear Inspection Chain Slipper Wear Inspection • • Visually inspect the drive chain guide and replace Visually inspect the upper and lower of the chain it if excessively worn or damaged. slipper on the swingarm and replace them if worn or damaged.
  • Page 95 MAINTENANCE AND ADJUSTMENT Sprocket Teeth Wear A. Good Teeth B. Worn Teeth C. Damaged Teeth NOTE ○ Sprocket wear is exaggerated in the illustration. Chain Lubrication Lubrication of the drive chain is necessary after rid- ing in the rain or mud, or any time the chain appears dry with a high quality lubricant for drive chains.
  • Page 96: Handlebars

    MAINTENANCE AND ADJUSTMENT Handlebars To suit various riding positions, the handlebars can be adjusted by turning the handlebar holders around. • Remove the handlebar pad. • Check the handlebars for bent or crack. • Remove the handlebar clamp bolts, the clamps and the handlebars.
  • Page 97 MAINTENANCE AND ADJUSTMENT • Tightening Torque Check the front brake for the proper brake effect, or no brake drag. Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) NOTE ○ Tighten the two clamp bolts alternately two times to ensure even tightening torque. A.
  • Page 98: Brakes

    Have the brake checked immedi- the rider’s preference. • ately by an authorized Kawasaki dealer. To adjust the brake lever position, slide the front brake lever dust cover back, and loosen the lock- nut, and turn the adjuster to either side with a Disc Brake Fluid wrench.
  • Page 99 MAINTENANCE AND ADJUSTMENT NOTICE Do not spill brake fluid onto any painted sur- face. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the brake sys- tem fittings.
  • Page 100 A. Front Brake Reservoir B. Upper Level Line than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement should be done by an authorized Kawasaki dealer. A. Rear Brake Reservoir B. Upper Level Line...
  • Page 101: Steering

    MAINTENANCE AND ADJUSTMENT Usable Brake Pad Range Steering The steering should always be kept adjusted so that the handlebars will turn freely but not have ex- cessive play. Steering Inspection • To check the steering adjustment, raise the front wheel off the ground using a jack (special tool: 57001-1238) and attachment (special tool: 57001 -1608).
  • Page 102 MAINTENANCE AND ADJUSTMENT A. Push and Rock A. Clamp B. Bolt C. Projections Steering Adjustment • D. Number Plate Raise the front wheel off the ground using a jack • (special tool: 57001-1238) and attachment (spe- Remove the handlebars (see Handlebars sec- cial tool: 57001-1608).
  • Page 103 MAINTENANCE AND ADJUSTMENT • Turn the steering stem locknut with a stem nut wrench (special tool: 57001-1100) to obtain the proper adjustment. A. Steering Stem Head B. Steering Stem Head Nut C. Front Fork Clamp Bolts (Upper) A. Steering Stem Locknut B.
  • Page 104: Front Suspension

    • Visually inspect the front fork for oil leakage, scor- ing or scratches on the outer surface of the inner tube. • If necessary, repair or replace by an authorized Kawasaki dealer.
  • Page 105 MAINTENANCE AND ADJUSTMENT on your KX will get stiffer as the race progresses. Therefore, it is not recommended to increase the air pressure for additional springing. The KX forks are designed to function without added air. • Rebound Damping Adjustment (Left Fork only) This adjustment affects how quickly the fork re- bounds.
  • Page 106 MAINTENANCE AND ADJUSTMENT setting, turning it clockwise 40 or more clicks (de- air pressure relief screw located in left front fork base pending on the model) is the hardest setting. valve assembly and right front fork top plug. Make • Fork Oil Amount Adjustment sure the front forks are fully extended with the front The fork oil amount affects only the final 100 mm...
  • Page 107 MAINTENANCE AND ADJUSTMENT NOTICE Do not force the rebound damping adjuster beyond the fully seated position, or the ad- justing mechanism may be damaged. A. Screw B. Front Fork Top Plug C. Front Fork (Right Side) Rebound Damping Adjustment (Left Fork only) •...
  • Page 108 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings with a standard tip screwdriver. Adjust the com- pression damping to suit your preference under certain conditions. NOTICE Do not force the compression damping ad- juster beyond the fully seated position, or the adjusting mechanism may be damaged.
  • Page 109 MAINTENANCE AND ADJUSTMENT Spring Preload Adjustment (Right Fork only) Compression Damping Adjuster Settings • To adjust the spring preload, turn the adjuster on the right front fork top plug with a wrench. Adjust the spring preload to suit your preference under certain conditions.
  • Page 110 MAINTENANCE AND ADJUSTMENT Front Fork Oil Change Spring Preload Adjuster Settings • Thoroughly clean the forks before disassembly. NOTICE Be careful not to scratch the inner tube and not to damage the dust seal. Avoid scratching or damaging the inner tube or the dust seal.
  • Page 111 MAINTENANCE AND ADJUSTMENT A. Front Fork Clamp Bolts (Upper) A. Front Axle Nut B. Top Plug Wrench (Special Tool: 57001-1645) B. Left Front Axle Clamp Bolts (Loosen) C. Bolts • Support the motorcycle using a jack (special tool: D. Front Brake Caliper 57001-1238) and attachment (special tool: 57001 E.
  • Page 112 MAINTENANCE AND ADJUSTMENT A. Right Front Axle Clamp Bolts (Loosen) A. Front Fork Clamp Bolts (Lower) B. Front Axle B. Pull down by twisting. C. Collar C. Front Fork Tube • • Loosen the front fork clamp bolts (lower). Measure each length between the axle holder and •...
  • Page 113 MAINTENANCE AND ADJUSTMENT Left Front Fork • Using the top plug wrench (special tool: 57001 -1645), remove the left front fork cylinder unit from the outer tube and slowly slide down the outer tube. A. Length B. Axle Holder C. Front Fork Outer Tube A.
  • Page 114 MAINTENANCE AND ADJUSTMENT A. Fork Oil A. Left Front Fork Cylinder Unit B. Left Front Fork Outer Tube • Temporarily install the left front fork cylinder unit to C. Top Plug Wrench (Special Tool: 57001-1645) the outer tube using the top plug wrench (special •...
  • Page 115 MAINTENANCE AND ADJUSTMENT NOTICE NOTE ○ Protect the axle holder with a soft jaw or heavy When loosening the locknut, the threads of cloth when using a vise. the axle holder do not touch the push rod. • If the push rod is scratched, it is possible to Loosen the adjuster assembly completely.
  • Page 116 MAINTENANCE AND ADJUSTMENT • • Remove the push rod. Remove the fork leg from the vise. • Unscrew the left front fork cylinder unit with the top plug wrench (special tool: 57001-1645). A. Push Rod A. Left Front Fork Cylinder Unit B.
  • Page 117 MAINTENANCE AND ADJUSTMENT • • Remove the left front fork cylinder unit from the Hold the front fork at the inverted position for more outer tube. than 20 minutes to allow the fork oil to fully drain. A. Left Front Fork Cylinder Unit...
  • Page 118 MAINTENANCE AND ADJUSTMENT • Holding the top plug wrench (special tool: 57001 -1645) with a vise, loosen the left front fork base valve assembly on the fork cylinder unit with a box wrench. A. Left Front Fork Base Valve Assembly B.
  • Page 119 MAINTENANCE AND ADJUSTMENT • Clean the threads of the left front fork cylinder unit and left front fork base valve assembly. A. Fork Oil B. Left Front Fork Cylinder Unit A. Threads • With the piston rod fully stretched, pour 330 mL (11.2 US oz.) of fork oil.
  • Page 120 MAINTENANCE AND ADJUSTMENT • Pump the piston rod slowly several times to expel air with plugged the oil hole by finger. A. Fork Oil B. Left Front Fork Cylinder Unit C. Oil Hole A. Pump B. Piston Rod Suspension Oil •...
  • Page 121 MAINTENANCE AND ADJUSTMENT A. 115 ∼ 123 mm (4.53 ∼ 4.84 in.) A. O-rings B. Oil Level B. Bushings • • Replace the O-rings on the left front fork base With the piston rod appear about 20 mm (0.79 in.) valve assembly with new ones.
  • Page 122 MAINTENANCE AND ADJUSTMENT A. Piston Rod A. Top Plug Wrench (Special Tool: 57001-1645) B. About 20 mm (0.79 in.) B. Left Front Fork Base Valve Assembly C. Left Front Fork Base Valve Assembly C. Left Front Fork Cylinder Unit D. Left Front Fork Cylinder Unit D.
  • Page 123 MAINTENANCE AND ADJUSTMENT • • Discharge the extra oil off the left front fork cylinder Drain the extra oil from the left front fork cylinder unit by pumping the piston rod to full stroke. unit oil hole. • Blow out the extra oil from the oil hole of the left NOTICE front fork cylinder unit with the compressed air blow to the oil hole.
  • Page 124 MAINTENANCE AND ADJUSTMENT • Protect the piston rod end with a heavy cloth to prevent damage. • Pump the piston rod to full stroke by pushing down the left front fork cylinder unit. • Check the piston rod for smooth operation. •...
  • Page 125 MAINTENANCE AND ADJUSTMENT • • Tighten the locknut fully and measure 10 ∼ 12 mm Completely wipe off the fork oil from the left front (0.39 ∼ 0.47 in.). fork cylinder unit. • Insert the cylinder unit into the fork. A.
  • Page 126 MAINTENANCE AND ADJUSTMENT WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an ac- cident resulting in injury. However, clamp- ing the axle holder too tightly can damage it which will affect riding stability.
  • Page 127 MAINTENANCE AND ADJUSTMENT A. Push Rod A. Left Front Fork Adjuster Assembly B. Left Front Fork Adjuster Assembly B. Locknut C. O-ring C. More Than 1 mm (0.04 in.) • • Slowly turn the left front fork adjuster assembly Turn the locknut counterclockwise until it contacts clockwise until resistance is felt and check the with the left front fork adjuster assembly.
  • Page 128 MAINTENANCE AND ADJUSTMENT NOTICE Tightening Torque Left Front Fork Adjuster Assembly: When tightening the locknut, the threads of 69 N·m (7.0 kgf·m, 51 ft·lb) the axle holder do not touch the push rod. If the push rod is scratched, it is possible to the damage in the cylinder unit.
  • Page 129 MAINTENANCE AND ADJUSTMENT A. Top Plug Wrench (Special Tool: 57001-1645) A. Left Front Fork Outer Tube B. Left Front Fork Cylinder Unit B. Fork Oil C. Left Front Fork Outer Tube Suspension Oil • Pour the specified amount of fork oil into the left SS-19 (1 L): P/No.
  • Page 130 MAINTENANCE AND ADJUSTMENT Right Front Fork • Using the top plug wrench (special tool: 57001 -1645), remove the right front fork spring adjuster unit from the right front fork outer tube and slowly slide down the outer tube. A. Left Front Fork Cylinder Unit B.
  • Page 131 MAINTENANCE AND ADJUSTMENT • Temporarily install the right front fork spring ad- juster unit to the outer tube using the top plug wrench (special tool: 57001-1645). A. Fork Oil A. Right Front Fork Spring Adjuster Unit B. Right Front Fork Outer Tube C.
  • Page 132 MAINTENANCE AND ADJUSTMENT • • Turn the right front fork spring preload adjuster Holding the top plug wrench (special tool: clockwise to the hardest position. 57001-1645) with a vise, remove the right front fork spring preload adjuster on the fork spring adjuster unit with a top plug wrench (special tool: 57001-1705).
  • Page 133 MAINTENANCE AND ADJUSTMENT WARNING When not using the Fork Spring Compressor (Special Tool: 57001-1771): If the axle holder is not securely clamped, the • Compress the outer tube by hands and install the front fork assembly may come out of the vise top plug wrench (special tool: 57001-1645) be- when compressed, which could cause an ac- tween the axle holder bottom and locknut.
  • Page 134 MAINTENANCE AND ADJUSTMENT • Hold the locknut with a wrench and remove the When using the Fork Spring Compressor right front fork bottom plug. (Special Tool: 57001-1771): • Set the fork spring compressor (special tool: NOTICE 57001-1771) and a suitable jack as shown in the figure.
  • Page 135 MAINTENANCE AND ADJUSTMENT A. Fork Spring Compressor (Special Tool: A. Holder Bar of Fork Spring Compressor (Special 57001-1771) Tool: 57001-1587) B. Heavy Cloth B. Holder of Fork Spring Compressor (Special Tool: 57001-1771) • Insert the holder bar of the fork spring compressor •...
  • Page 136 MAINTENANCE AND ADJUSTMENT WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an ac- cident resulting in injury. However, clamp- ing the axle holder too tightly can damage it which will affect riding stability.
  • Page 137 MAINTENANCE AND ADJUSTMENT • • Compress the outer tube with a suitable jack while Remove the right front fork spring adjuster unit, keeping the front fork upright, and remove the top collar, spring seat and fork spring. plug wrench (special tool: 57001-1645). •...
  • Page 138 MAINTENANCE AND ADJUSTMENT • • Hold the right front fork at the inverted position for Tighten the locknut fully. more than 20 minutes to allow the fork oil to fully drain. A. Locknut • Install the fork piston rod puller adapter (special tool: 57001-1791) to the threads on the fork piston rod puller (special tool: 57001-1289).
  • Page 139 MAINTENANCE AND ADJUSTMENT • Install the piston rod puller to the threads on the piston rod end. A. Fork Piston Rod Puller Adapter (Special Tool: 57001-1791) B. Fork Piston Rod Puller (Special Tool: A. Piston Rod Puller 57001-1289) B. Piston Rod...
  • Page 140 MAINTENANCE AND ADJUSTMENT • • Install the fork spring, spring seat, collar and Temporarily install the right front fork spring ad- spring adjuster unit to the outer tube. juster unit to the outer tube using the top plug wrench (special tool: 57001-1645). A.
  • Page 141 MAINTENANCE AND ADJUSTMENT WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an ac- cident resulting in injury. However, clamp- ing the axle holder too tightly can damage it which will affect riding stability.
  • Page 142 MAINTENANCE AND ADJUSTMENT A. Fork Spring Compressor (Special Tool: A. Holder Bar of Fork Spring Compressor (Special 57001-1771) Tool: 57001-1587) B. Heavy Cloth B. Holder of Fork Spring Compressor (Special Tool: 57001-1771) • Insert the holder bar of the fork spring compressor •...
  • Page 143 MAINTENANCE AND ADJUSTMENT WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an ac- cident resulting in injury. However, clamp- ing the axle holder too tightly can damage it which will affect riding stability.
  • Page 144 MAINTENANCE AND ADJUSTMENT • Slowly turn the bottom plug clockwise until resis- tance is felt and check the clearance between the locknut and bottom plug for more than 1 mm (0.04 in.). • Turn the locknut counterclockwise until it contacts with the bottom plug.
  • Page 145 MAINTENANCE AND ADJUSTMENT • When not using the Fork Spring Compressor Compress the outer tube with a suitable jack while (Special Tool: 57001-1771): keeping the front fork upright, and remove the top • Apply a non-permanent locking agent to the plug wrench (special tool: 57001-1645).
  • Page 146 MAINTENANCE AND ADJUSTMENT • WARNING Using the top plug wrench (special tool: 57001 -1645), remove the right front fork spring adjuster If the axle holder is not securely clamped, the unit from the outer tube and slowly slide down the front fork assembly may come out of the vise outer tube.
  • Page 147 MAINTENANCE AND ADJUSTMENT • Install the right front fork spring preload adjuster so that the projections align to the holes on the fork spring adjuster unit. A. Threads B. O-ring C. Right Front Fork Spring Preload Adjuster A. Projections B. Holes C.
  • Page 148 MAINTENANCE AND ADJUSTMENT • Pour the specified amount of fork oil into the right front fork outer tube. A. Top Plug Wrench (Special Tool: 57001-1645) B. Right Front Fork Spring Preload Adjuster C. Right Front Fork Spring Adjuster Unit A. Right Front Fork Outer Tube D.
  • Page 149 MAINTENANCE AND ADJUSTMENT Standard Oil 232 mL (7.84 US SOFT Amount oz.) (K = 9.2 227 ∼ 375 mL (7.67 Adjustable N/mm) ∼ 12.7 US oz.) Range Standard Oil 214 mL (7.24 US HARD Amount oz.) (K = 10.0 209 ∼ 357 mL (7.07 Adjustable N/mm) ∼...
  • Page 150 MAINTENANCE AND ADJUSTMENT NOTE Tightening Torque ○ The torque of left front fork cylinder unit and right Front Fork Clamp Bolts (Lower): 22 N·m (2.2 kgf·m, 16 ft·lb) front fork top plug are specified to 34 N·m (3.5 kgf·m, 25 ft·lb) however, when you use the top •...
  • Page 151 MAINTENANCE AND ADJUSTMENT • • Apply a non-permanent locking agent to the front Put the front wheel assembly between the fork fork clamp bolts (upper). legs, and insert the front brake disc into the front • Tighten the front fork clamp bolts (upper) to the brake pads.
  • Page 152 MAINTENANCE AND ADJUSTMENT A. Collars A. Pump the forks up and down. B. Caps B. Block C. Front Axle • Tighten the right front axle clamp bolts to the spec- D. Right Front Axle Clamp Bolts ified torque. E. Front Axle Nut F.
  • Page 153 MAINTENANCE AND ADJUSTMENT WARNING After servicing, it takes several applications of the brake lever before the brake pads con- tact the disc, which could result in increased stopping distance and cause an accident re- sulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc.
  • Page 154: Rear Suspension (uni-trak ® )

    Visually inspect the rear shock absorber for oil leakage. • If necessary, repair or replace by an authorized Kawasaki dealer. A. Rebound Damping Adjuster If the damping feels too soft or too stiff, adjust it in accordance with the following table.
  • Page 155 MAINTENANCE AND ADJUSTMENT NOTICE Rebound Damping Adjuster Settings Do not force the rebound damping force ad- juster beyond the fully seated position, or the adjusting mechanism may be damaged. NOTE ○ Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the com- pression damping force.
  • Page 156 MAINTENANCE AND ADJUSTMENT High Speed Compression Damping Adjuster Settings A. Compression Damping Adjuster for High Speed B. Compression Damping Adjuster for Low Speed If the damping feels too soft or too stiff, adjust it in A. Seated Position (Adjuster Turned Fully accordance with the following table.
  • Page 157 MAINTENANCE AND ADJUSTMENT NOTICE Low Speed Compression Damping Adjuster Settings Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. NOTE ○ Adjustment of the compression damping adjuster for the rear suspension will slightly affect the re- bound damping force.
  • Page 158 MAINTENANCE AND ADJUSTMENT • Using the hook wrench (special tool: 57001 -1539), turn the spring preload adjusting nut as required. Turning the adjusting nut down in- creases the spring preload. A. Spring Preload Adjusting Nut B. Locknut C. Hook Wrenches (Special Tools: 57001-1101, 1539) A.
  • Page 159 Removal and installation of the rear shock B. Center of Upper Rear Shock Absorber Pivot absorber spring should be performed by an C. Spring End authorized Kawasaki dealer. • Tighten the locknut securely. Tightening Torque Rear Shock Absorber Spring Locknut:...
  • Page 160: Wheels

    MAINTENANCE AND ADJUSTMENT rim to warp, the nipples and spokes to fatigue more Wheels quickly, and the spokes to break. Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track condi- tions and rider preference, but keep it close within the recommended range.
  • Page 161 MAINTENANCE AND ADJUSTMENT NOTE ○ The welding spot of the rim may show exces- sive runout. Disregard this when measuring rim runout. Rim Runout A. Bead Protector Nut Rim Runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout.
  • Page 162: Hoses Inspection

    MAINTENANCE AND ADJUSTMENT Hoses Inspection Check the brake and fuel hoses for cracks or de- terioration, and the connections for looseness in ac- cordance with the Periodic Maintenance Chart. • Inspect the brake hose and fittings for deteriora- tion, cracks and signs of leakage by bending or twisting the hoses.
  • Page 163: Tightening Torques Of Nuts And Bolts

    MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. 1.
  • Page 164 MAINTENANCE AND ADJUSTMENT 1. Steering Stem Head Nut 7. Rear Axle Nut 2. Front Master Cylinder Clamp Bolts 8. Rocker Arm Pivot Nut 3. Steering Stem Nut 9. Tie-Rod Mounting Nuts 4. Handlebar Holder Nuts 10. Rear Shock Absorber Nut 5.
  • Page 165 MAINTENANCE AND ADJUSTMENT Torque table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider.
  • Page 166 MAINTENANCE AND ADJUSTMENT Fastener N·m kgf·m ft·lb Remarks Handlebar Holder Nuts Steering Stem Head Nut Steering Stem Nut 0.50 43 in·lb Rear Frame Mounting Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 167: Cleaning Your Motorcycle

    Avoid all harsh chemicals, solvents, detergents, and household cleaning products such as ammo- General Precautions nia-based window cleaners. Frequent and proper care of your Kawasaki mo- • Gasoline, brake fluid, and coolant will damage the torcycle will enhance its appearance, optimize over- finish of painted and plastic surfaces: wash them all performance, and extend its useful life.
  • Page 168 The semi-gloss finish effect may be lost when it is Chrome and Aluminum excessively rubbed. Chrome and uncoated aluminum parts can be • If any doubt, consult an authorized Kawasaki treated with a chrome/aluminum polish. Coated dealer. aluminum should be washed with a mild neutral de- Painted Surfaces tergent and finished with a spray polish.
  • Page 169: Lubrication

    MAINTENANCE AND ADJUSTMENT Leather, Vinyl, and Rubber Lubrication If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner/treatment to clean and care for leather accessories. Washing Lubricate the areas shown in the illustrations of leather parts with detergent and water will damage this section with either motor oil or regular grease, them, shortening their life.
  • Page 170 MAINTENANCE AND ADJUSTMENT • • Rear Brake Pedal Shift Pedal • Rear Master Cylinder Joint Pin • Kick Pedal • Footpeg Apply an aerosol cable lubricant with a pressure lubricator on all cables: • Clutch Cable • Throttle Cable...
  • Page 171 MAINTENANCE AND ADJUSTMENT Cable Lubrication Apply grease to the following points: • Clutch Inner Cable Upper End • Throttle Inner Cable Upper End A. Upper End Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears dry with a high quality lubricant for drive chains.
  • Page 172: Dfi Self-diagnosis

    MAINTENANCE AND ADJUSTMENT DFI Self-Diagnosis This motorcycle equips the DFI trouble self -diagnosis system. Trouble diagnosis can be con- ducted with the optional parts sold separately as the following procedures. Self-diagnosis Outline The self-diagnosis has two modes and can be switched to another mode by grounding the self-diagnosis terminal.
  • Page 173 MAINTENANCE AND ADJUSTMENT Dealer Mode - Self-diagnosis Procedures • The orange FI warning indicator light emits service Disconnect the capacitor lead connector. code(s) to show the problem(s) which the DFI sys- tem, and ignition system has at the moment of diag- nosis.
  • Page 174 MAINTENANCE AND ADJUSTMENT • NOTE Connect the power supply harness (optional part: ○ 26011-0246) to the capacitor lead connector of the Use a fully charged battery when conducting self main harness. -diagnosis. Otherwise, the light blinks very slowly • Connect the power supply harness (optional part: or doesn’t blink.
  • Page 175 MAINTENANCE AND ADJUSTMENT • To enter the self-diagnosis dealer mode, ground the self-diagnosis terminal for more than 2 sec- onds, and then keep it grounded continuously. • Count the blinks of the orange light to read the service code. Keep the lead ground until you finish reading the service code.
  • Page 176 MAINTENANCE AND ADJUSTMENT How to Read Service Codes • Service codes are shown by a series of long and short blinks of the orange FI warning indicator light as shown below. • Read 10th digit and unit digit as the orange FI warning indicator light blinks. •...
  • Page 177 MAINTENANCE AND ADJUSTMENT NOTE ○ Even if the battery or the ECU are disconnected, or the problem is solved, all service codes remain in the ECU. Service Code Table Service Orange FI Warning Indicator Light Problems Code Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open...
  • Page 178 MAINTENANCE AND ADJUSTMENT Service Orange FI Warning Indicator Light Problems Code Upstream injector malfunction, wiring open or short Fuel pump malfunction, wiring open or short Ignition coil malfunction, wiring open or short NOTE ○ The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply.
  • Page 179: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE Spark missing or weak: • ○ Spark plug dirty, broken, or gap improperly ad- This troubleshooting guide is not exhaustive and justed does not give every possible cause for each prob- • Spark plug cap or high-tension wiring defective lem listed.
  • Page 180 TROUBLESHOOTING GUIDE • • Cylinder head warped Valve not seating properly (valve bent, worn, or • Cylinder gasket damaged carbon accumulation on the seating surface) • • Decompression trouble Piston ring worn, weak, broken, or sticking • Piston ring side clearance excessive Poor low-speed performance - •...
  • Page 181 TROUBLESHOOTING GUIDE • Fuel/air mixture incorrect: Engine oil level too high • • Air cleaner element clogged, poorly sealed, or not Engine oil viscosity too high • installed Crankshaft bearing worn or damaged • • Fuel contaminated with water or foreign matter Drive chain trouble •...
  • Page 182 TROUBLESHOOTING GUIDE • Clutch hub nut loose • Lubrication inadequate: Clutch plate warped or rough • • Engine oil level too low Clutch hub spline damaged • Engine oil quality poor or type incorrect Gear shifting faulty - Coolant inadequate: Transmission does not go into gear;...
  • Page 183 TROUBLESHOOTING GUIDE • Engine noise abnormal - Camshaft chain, sprocket, chain guide worn • Decompression spring broken Knocking: • Flywheel magneto loose • Carbon built up in combustion chamber • Fuel quality poor or type incorrect Abnormal drive train noise - •...
  • Page 184 TROUBLESHOOTING GUIDE • Rear shock absorber noise: Steering stem bearing damaged • • Shock absorber damaged Steering stem bearing inadequately lubricated • Steering stem bent • Disc brake noise: Tire air pressure too low • Pad installed incorrectly • Pad surface glazed Handlebars shakes or vibrates excessively: •...
  • Page 185 TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension Poor braking performance - too soft): • Air in the brake line • Front fork oil level insufficient and/or front fork • Brake pad or disc worn leaking oil • Brake fluid leaking • Front fork oil viscosity too low •...
  • Page 186: Tuning

    TUNING TUNING • The front and rear suspension should always be Suspension balanced; when the one is changed, the other one might need to be changed similarly. • When evaluating suspension performance, the Introduction rider must make every effort to ride consistently No area of machine adjustment is more critical and to recognize the effects of his input.
  • Page 187 TUNING Troubleshooting Improper Settings does not feel as “hard” in the later stage of fork travel. Listed below are some symptoms of improper sus- Fork Oil Amount Effect on Fork Stroke pension settings and the most likely means of cor- recting them.
  • Page 188 TUNING • Springs too soft Hence, if the actual rider weighs considerably more • Fork oil deteriorated or less, or if his riding experience and ability are • Rebound and/or compression damping improperly much above or below the intermediate level, it is adjusted.
  • Page 189 TUNING Front and Rear Suspension Compatibility Suspension Tuning According the Type of Inspection Course Use this procedure to determine if the suspension Lower the front end slightly is balanced reasonably well. (Increase the amount of fork • Hold the motorcycle upright (remove the side tube protrusion above the stand.).
  • Page 190 TUNING • Although this is one of the most effective adjust- Decrease the fork oil amount. • ment procedures, suspension settings may vary de- Use a softer spring, or decrease the spring pending on the conditions at the track and the rider’s preload.
  • Page 191 TUNING • Increase the rebound damping. Rear End Bottoms After 3 or 4 Successive • Decrease the rear shock absorber spring preload. Jumps - • • Decrease the compression damping. Decrease the rebound damping. NOTE Front and Rear Ends Bottom Off After a ○...
  • Page 192: Gearing

    TUNING • Since it is difficult to set the machine so it is best Gearing suited for all portions of the circuit, determine which circuit portions will have the greatest ef- fect on lap time, and tune the machine to these Selection of the Secondary Reduction Ratio portions.
  • Page 193: Special Care According To Track Conditions

    TUNING Take care not to overheat the engine in these con- Special Care According to Track ditions. The engine also works very hard when Conditions riding in deep sand. • In muddy or sandy conditions, increase chain • slack as the chain and sprockets will be packed In dry, dusty conditions (such a volcanic ash or fine powdery dust), special care must be given to with mud or sand, which reduces chain slack.
  • Page 194: Optional Parts

    OPTIONAL PARTS OPTIONAL PARTS Engine Sprocket Suspension Spring (N/mm) K = 9.2 13T (Standard) Front K = 9.6 (Standard) Rear Sprocket K = 10.0 K = 49 K = 51 Rear Aluminum 50T (Standard) K = 53 (Standard) K = 55 Disc Plate Front No holes (for wet conditions)
  • Page 195: Pre-race Checks And After-race Maintenance

    PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE Pre-Race Checks - Maintenance After the First Race - • • Front axle nut, or axle clamp bolt torque Clean the air cleaner element. • • Front fork clamp bolt torque Adjust the drive chain slack.
  • Page 196 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE • • Apply grease to swingarm and rear suspension Chain case • pivots. Front fork springs (for suspension adjustment) • • Inspect the drive chain and rear sprocket for wear. Rear shock absorber springs (for suspension ad- •...
  • Page 197: Storage

    STORAGE STORAGE WARNING Before Storage Gasoline is extremely flammable and can be explosive under certain conditions, creating When the motorcycle is to be stored for any length the potential for serious burns. Always stop of time, it should be prepared for storage as follows. the engine and never smoke while handling •...
  • Page 198: After Storage

    STORAGE • Fill the fuel tank with fuel. • After Storage Check all the points listed in the Daily Pre-Ride Checks section. • • Remove the plastic bag from the muffler. Perform a lubrication procedure in the Lubrication • Make sure the spark plug is tight. section.
  • Page 199: Environmental Protection

    Properly discard used tires, engine oil, other vehicle components, or the entire vehicle that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure.
  • Page 200: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM...

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