Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Engine Right Side Engine Removal/Installation Engine Bottom End/Transmission 8 j Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix...
LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC 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 direct current...
NOTE maintenance. ○ • This note symbol indicates points of par- Use proper tools and genuine Kawasaki mo- ticular interest for more efficient and con- torcycle parts. Special tools, gauges, and venient operation. testers that are necessary when servicing •...
GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information-Air Oil Separate System Inverted Front Fork ........1-11 Unit Conversion Table ......................1-13...
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
Replacement Parts Replacement Parts must be KAWASAKI genuine or rec- ommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice initial tightening and final tightening with torque wrench.
GENERAL INFORMATION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Leads A two-color lead is identified first by the primary color and then the stripe color.
1-8 GENERAL INFORMATION General Specifications KX250R6F ∼ Items KX250-R1 Dimensions Overall Length 2 185 mm (86.0 in.) Overall Width 840 mm (33.1 in.) 815 mm (32.1 in.) Overall Height 1 265 mm (49.8 in.) Wheelbase 1 480 mm (58.3 in.) Road Clearance 340 mm (13.4 in.)
GENERAL INFORMATION 1-9 General Specifications KX250R6F ∼ Items KX250-R1 Transmission: Type 5 speed, constant mesh, return shift Gear Ratios: 1.800 (27/15) 1.437 (23/16) 1.176 (20/17) 1.000 (21/21) 0.869 (20/23) Final Drive System: Type Chain drive Reduction Ratio 3.923 (51/13) Overall Drive Ratio 10.234 @Top gear...
1-10 GENERAL INFORMATION General Specifications KX250R6F ∼ Items KX250-R1 Effective Disc Diameter: Front 225 mm (8.9 in.) Rear 215 mm (8.5 in.) Specifications are subject to change without notice, and may not apply to every country. EUR: Europe Model US: United States Model...
GENERAL INFORMATION 1-11 Technical Information-Air Oil Separate System Inverted Front Fork This model has newly developed “air oil separate” inverted front fork. Outline The design of the newly developed “air oil separate” inverted front fork aims at the improvement of front suspension performance required for motocross racing.
1-12 GENERAL INFORMATION Technical Information-Air Oil Separate System Inverted Front Fork Air Oil Separate System Inverted Front Fork Diagram 1. Cylinder Unit 8. Fork Spring 2. Outer Chamber 9. Travel Control Valve 3. Oil Chamber 10. Inner Tube 4. Oil Seal 11.
GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Each Every 3 Every 6 Every 12 race races races races (or 2.5 (or 7.5 (or 15 (or 30 Page...
2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Each Every 3 Every 6 Every 12 race races races races (or 2.5 (or 7.5 (or 15 (or 30 Page OPERATION hours) hours) hours) hours) • Rear shock oil - replace 2-52 • Fuel system - clean 2-16 Fuel hose - replace...
Retaining Plate Bolts 0.60 52 in·lb Subexhaust Valve Cover Bolts 0.90 78 in·lb Cylinder Head Nuts KX250-R1 with KX250R6F ∼ 2.3 mm Washer Engine Mounting Bracket Nuts (Frame Side 8 mm) Engine Mounting Bracket Nuts (Engine Side 10 KIPS Cover Bolts 0.60...
2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sublever Allen Bolt 0.40 35 in·lb Main Lever Allen Bolt 0.40 35 in·lb Stopper Pin Allen Bolt 0.40 35 in·lb Cylinder Nuts Muffler Damper Mounting Bolt 0.90 78 in·lb Expansion Chamber Mounting Bolt Muffler Mounting Bolts...
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Wheels/Tires Front Axle Nut Front Axle Clamp Bolts 14.5 Rear Axle Nut 11.0 Not less Not less Not less Spoke Nipple than 2.2 than 0.22 than 19 in·lb Final Drive Rear Axle Nut 11.0...
PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Air Cleaner Element Oil High quality foam air filter oil – – – Read Valve Warp 0.5 mm (0.020 in.) Cooling System...
Oil Viscosity KHL15-10 (KAYABA 01) or equivalent Oil Quantity: (Adjustable range) Outer (Outer/Inner Tubes): 280 ∼ 320 mL KX250-R1 300 mL (10.14 US oz.) (9.47 ∼ 10.82 US oz.) KX250R6F ∼ 290 ∼ 330 mL 310 mL (10.48 US oz.) (9.80 ∼...
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Check ○ Check the fuel hose periodically in accordance with the Periodic Maintenance Chart, and if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst.
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures If the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable, use the cable adjuster [A] at the carburetor. • Pull the boot off of the carburetor top. Make the necessary free play adjustment at the lower cable adjuster, tighten the locknut [B], and install the boot.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection The air cleaner element should be cleaned and oiled before each race or practice session. A dirty or improperly oiled element can diminish engine performance, cause spark plug fouling, and could affect long term durability of the engine.
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Clean the element [A] in a bath of a high-flash-point sol- vent using a soft bristle brush. • Squeeze it dry in a clean towel [A]. Do not wring the ele- ment or blow it dry; the element can be damaged. •...
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Tank and Tap Cleaning WARNING Clean the fuel tank in a well-ventilated area, and take care that there is 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 solvent to clean the tank.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Cooling System Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart. WARNING 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.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Draining The coolant should be changed periodically to ensure long engine life. WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot.
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Install the drain plug. ○ Replace the gasket with a new one. Torque - Coolant Drain Plug on Water Pump Cover: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Fill the radiator up to the bottom of the radiator filler neck [B] with coolant [A], and install the cap, turning it clockwise about 1/4 turn.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Cylinder Head Warp Inspection • Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and the head.
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Piston/Cylinder Clearance The piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced. If only a piston is replaced, the clearance may exceed the standard slightly.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder [B], using the piston to locate the ring squarely in place. • Set it close to the bottom of the cylinder, where cylinder wear is low.
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Exhaust System • The exhaust system, in particular, the baffle is equipped in the muffler body to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the baffle, ex- haust efficiency is reduced, causing engine performance to drop.
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Lever Free Play Check • Slide the clutch lever dust covers [A] out of place. • Check that the clutch cable upper end is fully seated in the adjusting bolt [B]. • Check that the clutch lever [C] has 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play [D].
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Friction and Steel Plates Wear, Damage Inspection • Visually inspect the friction and steel plates to see if they show any signs of seizure, or uneven wear. If any plates show signs of damage, replace the friction plates and steel plates as a set.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Transmission Oil Level Inspection • Situate the motorcycle so that it is perpendicular to the ground. • If the motorcycle has just been used, wait several minutes until the oil settles. • Check that the oil level comes up between the upper level [A] and lower level [B] through the oil level gauge [C] on the clutch cover.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Wheel/Tires Air Pressure Inspection/Adjustment • Using tire air pressure gauge [A], measure the tire pres- sure when the tires are cold. Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from the recom- mended pressure.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Wheel/Bearing Inspection • Using a jack, raise the front wheel off the ground (see Wheels/Tires chapter). Special Tool - Jack: 57001-1238 • Turn the handlebar all the way to the right or left. • Hold the front fork leg and move [A] the front wheel side- ways with force to inspect the roughness of the hub bear- ing.
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Adjustment • Loosen the left and right chain adjuster locknuts [A]. • Remove the cotter pin [B] and loosen the axle nut [C]. If the chain is too tight, turn in the left and right chain adjusting bolts [D] evenly, and push the wheel forward until the chain is too loose.
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Chain Wear Inspection • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. [A] Bushing [B] Roller [C] Pin...
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Sprocket Wear Inspection • Visually inspect the front and rear sprocket teeth for wear and damage. If they are worn as illustrated or damaged, replace the sprocket. A. Worn Tooth (Engine Sprocket) B. Worn Tooth (Rear Sprocket) C.
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Adjust the front brake lever [A] to suit you. • Slide the brake lever dust cover [B] out of place. • Loosen the adjuster locknut [C] and turn the adjuster [D] to either side. •...
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection In accordance with the Periodic Maintenance Chart, in- spect the brake fluid level in the front or rear brake fluid reservoirs. • Check the brake fluid level in the front or rear brake reser- voir [A].
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed.
2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. • Remove the screw [A], reservoir cap [B] and diaphragm [C].
PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Change the brake fluid as follows: ○ 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.
2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Master Cylinder Cup and Dust Cover Replacement • Remove the front master cylinder (see Brake chapter). • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container. • Unscrew the locknut and pivot bolt, and remove the brake lever.
PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Replace the piston, secondary cup, primary cup and spring as a set with a new one. • Replace the dust cover with a new one. • Apply brake fluid to the removed parts and to the inner wall of the cylinder.
2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Pull out the piston [A] by hand. • Remove the dust seals [B] and fluid seals [C]. NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper.
PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Replace the fluid seal(s) [A] with new ones. ○ Apply brake fluid to the fluid seal(s), and install them into the cylinders by hand. • Replace the dust seal(s) [B] with new ones. ○...
2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the shaft rubber boot [A] and dust cover [B] if they are damaged. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-resistance grease).
PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Remove each banjo bolts [A] and washers [B]. • Replace the washers with new ones. For Front Brake • Remove Bolts [A] Brake Hose Clamps [B] For Rear Brake • Remove: Master Cylinder [A] Hose Clamps [B] Caliper Cover [C] Rear Wheel [D]...
2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Inspection • Holding the brake lever, compress the front fork several times to check for smooth operation. • Visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tube [A]. If necessary, repair any damage.
PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Using the special tool [A], remove the fork top plug [B] (subtank) from the outer tube and slowly slide down the outer tube [C]. Special Tool - Top Plug Wrench, 46 mm: 57001-1622 •...
[A]. Special Tool - Top Plug Wrench, 46 mm: 57001-1622 [B] • Remove: Cylinder Unit [A] Spring Collar [B] (KX250-R1) Fork Spring [C] Spring Collar [D] CAUTION Disassembling the cylinder unit can lead to trouble. Do not disassemble the cylinder unit.
PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Holding the top plug wrench [A] with a vise, loosen the base valve assembly [B] on the subtank [C]. Special Tool - Top Plug Wrench, 46 mm: 57001-1622 [B] • Remove the base valve assembly [A] from the subtank [B].
2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the piston rod in fully compressed position, pour the specified amount of fork oil [A]. Recommended Oil: KHL15-10 (KAYABA01) or equivalent Recommended Quantity: 160 ml (5.41 US oz.) NOTE ○ Plug the two oil holes [B] on the subtank [C] with fingers. •...
PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Holding the top plug wrench [A] (special tool) with a vise. • Holding the subtank [B] with the top plug wrench, torque the base valve assembly [C]. Special Tool - Top Plug Wrench, 46 mm: 57001-1622 Torque - Base Valve Assembly: 27 N·m (2.8 kgf·m, 20 ft·lb) •...
Make sure about 16 mm (0.63 in.) [A] of push rod thread is exposed from the lock nut [B]. • Completely wipe of the fork oil from the following parts. Cylinder Unit [A] Spring Collar [B] (KX250-R1) Fork Spring [C] Spring Collar [D] • Insert above-mentioned parts into the fork.
Special Tool - Top Plug Wrench, 46 mm: 57001-1622 • Pour [A] the specified amount of fork oil into the outer tube. Recommended Oil: KHL15-10 (KAYABA01) or equivalent Recommended Quantity: KX250-R1: 300 mL (10.14 US oz.) KX250-R2 ∼: 310 mL (10.48 US oz.)
2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the outer tube and temporarily tighten the fork top plug (subtank). Special Tool - Top Plug Wrench, 46 mm: 57001-1622 • After installing the front fork, torque the top plug [A]. Special Tool - Top Plug Wrench, 46 mm: 57001-1622 [B] The torque of fork top plug is specified to 29 N·m (3.0 kgf·m, 22 ft·lb) however, when you use the top plug wrench (special tool) [A], reduce the torque to 90% of the spec-...
PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Adjust the gas reservoir damping adjusters [A] to the soft- est position. • Remove the air bleeder bolt [B] and pump the rear shock to drain the oil out the rear shock body. •...
2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Visually inspect the piston [A], O-ring [B], and oil seal assy [C]. • If the piston, O-ring and oil seal assy are badly scored, rusty or damaged, replace them. • Using the grinder, shave off the stopper portion [A] of the rod.
PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Check the circlip for weakening, deformity and flaws. If necessary, replace it with a new one. CAUTION If weakened, deformed or flawed circlip is used, the gas reservoir cap may not hold when injecting the nitrogen gas.
2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert the piston end [A] of the piston rod assembly into the rear shock body [C] slowly. Do not insert the seal assembly [B] yet. Pump the piston rod until all the air is forced out of the rear shock body.
PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Swingarm and Uni-Trak Linkage Inspection • 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 •...
2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures KX250-R1: • Remove: Number Plate [A] Handlebar Holder Bolts [B] Handlebar Holder [C] Handle Bar [D] • Pull out the breather hose [E]. KX250R6F ∼: • Remove: Number Plate [A] Pad [B] Handlebar Holder Bolts [C]...
PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures KX250-R1: • Install the handlebar [A] on the handlebar holder as shown. Same Length [B] Bridge Bar [C] • Install the handlebar holder [A] together with the handle- bar so that the mark side [B] on the holder points at the rear.
2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Stem Bearing Lubrication • Remove the steering stem (see Steering Stem Removal in Steering chapter). • 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.
PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Measure the gap [A] with a wire-type thickness gauge to prevent possible damage to the platinum electrode. If the gap is incorrect, replace it with the standard plug. Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) Standard: •...
2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Cable Lubricant Throttle Cables Clutch Cable • Lubricate the cables by seeping the oil between the inner cable and cable housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Throttle Cable Installation ....................Throttle Cable Lubrication....................Carburetor ..........................Idle Speed Inspection ....................... Idle Speed Adjustment......................
3-8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle.
FUEL SYSTEM 3-9 Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber.
3-10 FUEL SYSTEM Carburetor • Hold the gauge vertically against the side of the carbure- tor body so that the “zero” line [C] is several millimeters higher than the bottom edge [D] of the carburetor body. • Turn the fuel tap to the ON position to feed fuel to the carburetor.
FUEL SYSTEM 3-11 Carburetor • Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 6.5 ±1 mm (0.256 ±0.039 in.) NOTE ○...
3-12 FUEL SYSTEM Carburetor • Loosen the clamps [A]. • Remove: Right Side Cover Muffler Rear Frame Bolts [A] (Left and Right) ○ Loosen the rear frame bolts [B], pull up the rear frame [C] with the air cleaner housing and remove the carburetor. •...
FUEL SYSTEM 3-13 Carburetor Carburetor Installation • Lifting up the link shaft end [A] of the throttle sensor install the throttle valve assembly. • Being careful not to bend or otherwise damage the jet needle. Check to see that the throttle valve [B] goes all the way down into the carburetor body, and slides smoothly.
3-14 FUEL SYSTEM Carburetor • Turn the fuel tap to the OFF position. • Remove the carburetor. • Place a suitable container beneath the carburetor. • Remove the drain plug [A] from the bottom of the float bowl and check for water or dirt in the fuel. If any water or dirt comes out, clean the carburetor, fuel tap and fuel tank (see this chapter).
FUEL SYSTEM 3-15 Carburetor • Remove the fuel cut valve [A] from the carburetor. • Remove the throttle sensor mounting bolt [A]. • Before removing the throttle sensor [B], mark [C] the car- buretor body and sensor so that it can be installed later in the same position.
3-16 FUEL SYSTEM Carburetor Carburetor Assembly • Clean the disassembly parts before assembling. • Replace the O-rings with a new one if it is deteriorated or damaged. • Turn in the air screw [A] fully but not tightly, and then back it out the specified number of turns.
FUEL SYSTEM 3-17 Carburetor • Remove the carburetor. • Before disassembling the carburetor, check the fuel level (see Fuel Level Inspection). If the fuel level is incorrect, inspect the rest of the carbu- retor before correcting it. • Pull the carburetor cable to check that the throttle valve [A] moves smoothly and returns by spring pressure.
3-18 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal • Remove: Side Covers (see Frame chapter) Seat (see Frame chapter) Muffler (see Engine Top End chapter) Bolts and Rear Fender [A] (see Frame chapter) Screws and Rear Flap [B] (see Frame chapter) Rear Frame Mounting Bolts [C] •...
FUEL SYSTEM 3-19 Air Cleaner Element Installation • When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits. •...
3-20 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
3-22 FUEL SYSTEM Reed Valve Reed Valve Removal • Remove the carburetor. • Remove the holder mounting bolts [A], and take off the carburetor holder [B]. • Take the reed valve [A] out of the cylinder. Reed Valve Installation • Tighten the carburetor holder mounting bolts.
COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Air Bleeding........................Cooling System Pressure Testing ..................Cooling System Flushing ....................Disassembly and Assembly Precautions................
4-4 COOLING SYSTEM Specifications Item Service Limit Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed Ratio Soft water 50%, antifreeze 50% Total Amount 1.20 L (1.27 US qt.) Radiator 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi) Cap Relief Pressure...
4-6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart (see Periodic Maintenance chapter). WARNING 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.
COOLING SYSTEM 4-7 Coolant 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 cool- ing system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the effi- ciency of the cooling system.
4-8 COOLING SYSTEM Disassembly and Assembly Precautions • Prior to disassembly of cooling system parts (radiator, pump, etc), wait until the coolant cools down, and then drain the coolant. • After assembling and filling the system with coolant, bleed any air from the system.
COOLING SYSTEM 4-9 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Draining). • Loosen the cooling hose clamps [A], and disconnect the cooling hoses on the water pump cover [B]. • Unscrew the cover bolts [C], and remove the water pump cover.
4-10 COOLING SYSTEM Water Pump Impeller Inspection • Visually check the impeller [A]. If the surface is corroded, or if the blades [B] are dam- aged, replace the impeller. Water Pump Shaft Removal • Remove: Right Engine Cover (see Engine Right Side chapter) •...
COOLING SYSTEM 4-11 Water Pump • Insert a bar [A] into the water pump shaft hole from the inside of the right engine cover, and remove the oil seal [B] by tapping [C] evenly around the seal lips. Oil Seal Installation CAUTION If the oil seal or ball bearing is removed, replace all of them with new ones at the same time...
4-12 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining) • Remove: Radiator Shrouds Fuel Tank (see Fuel System chapter) • Unscrew the clamps [A] and the bolts [B]. • Remove the radiator screens [C]. • Unscrew the bolts [A]. •...
COOLING SYSTEM 4-13 Radiator Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins are deformed, carefully straighten them with the thin blade of a screwdriver [A]. CAUTION Do not tear the radiator tubes while straightening the fins.
4-14 COOLING SYSTEM Radiator Filler Neck Inspection • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.
ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Cylinder Head......................... Cylinder Compression Measurement................Cylinder Head Removal ....................Cylinder Head Installation ....................Cylinder Head Warp Inspection ..................Cylinder ..........................Cylinder Removal......................Cylinder Installation......................Piston Removal.........................
5-6 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. •...
5-8 ENGINE TOP END Cylinder Cylinder Removal • Drain the coolant (see Cooling System chapter). • Remove the cylinder head (see this chapter). • Remove the cooling hoses. • Unscrew the KIPS cover bolts [A] and remove the KIPS cover [B]. •...
ENGINE TOP END 5-9 Cylinder • Check to see that the pin [A] in each piston ring groove is between the ends of the piston ring, and fit the base of the cylinder over each ring, pressing in on opposite sides of the ring as necessary.
5-10 ENGINE TOP END Cylinder Piston Installation • Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase. • Scrape off any carbon of the piston, then lightly polish the piston with fine emery cloth.
ENGINE TOP END 5-11 Cylinder Cylinder Wear Inspection • Refer to the Cylinder Wear Inspection in the Periodic Maintenance chapter. Piston Diameter Measurement • Refer to the Piston Diameter Measurement in the Periodic Maintenance chapter. Piston/Cylinder Clearance • Refer to the Piston/Cylinder Clearance in the Periodic Maintenance chapter.
ENGINE TOP END 5-13 Exhaust Valve (KIPS) • Pull out the exhaust valve shaft [A] from the cylinder. • Remove: Sublever (Right) [B] Collar [C] Main Lever [D] with Spring Sublever (Left) [E] • Pull out: Main Exhaust Valves [A] Subexhaust Valves [B] Exhaust Valve Installation •...
Set the sublever (left), aligning its hook portion [C] with the pin [D] of the subexhaust valve. [E] Apply a 2-stroke engine oil. [F] Front KX250-R1: • Install the subexhaust valve covers on the cylinder. ○ Set the gasket [A] on the valve cover [B] as shown.
ENGINE TOP END 5-15 Exhaust Valve (KIPS) ○ Insert the springs [A] and valve cover with gasket. ○ Tighten the subexhaust valve cover bolts [B]. Torque - Subexhaust Valve Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) NOTE ○ Be careful not to bite the gasket [C] when installing the subexhaust cover bolts.
5-16 ENGINE TOP END Exhaust Valve (KIPS) • Apply a high temperature grease to the oil seal lip [A]. • Apply a 2-stroke engine oil to the surfaces [B] of the ex- haust valve shaft [C], shown with X marks. •...
ENGINE TOP END 5-17 Exhaust Valve (KIPS) • Install the cylinder (see Cylinder Installation) Torque - Cylinder Nuts: 33 N·m (3.4 kgf·m, 25 ft·lb) • Set the spring [A] as shown. [B] Governor Shaft Lever [C] Exhaust Valve Shaft • Using a 14 mm open-end wrench [D], install the governor shaft lever [B] as shown.
5-18 ENGINE TOP END Muffler (Expansion Chamber, Muffler Body) Muffler Removal • Remove: Right Radiator Shroud Right Side Cover Springs [A] on Connecting Seal • Remove the mounting bolts [A] and pull the muffler body [B] off toward the rear. •...
ENGINE TOP END 5-19 Muffler (Expansion Chamber, Muffler Body) • Hook [A] the spring side which turns freely to the expan- sion chamber. • Tighten: Torque - Muffler Damper Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install the springs [A] on connecting seal [B], as shown. [C] Expansion Chamber [D] Muffler Body NOTE...
6-8 ENGINE RIGHT SIDE Clutch Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING To avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment.
ENGINE RIGHT SIDE 6-9 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Bottom End/Transmis- sion chapter). • Remove the brake pedal (see Brake chapter). • Unbolt the clutch cover bolts [A], and take off the clutch cover [B].
6-10 ENGINE RIGHT SIDE Right Engine Cover Right Engine Cover Removal • Remove: Engine Oil (drain) (see Engine Bottom End/Transmis- sion chapter) Coolant (drain) (see Cooling System chapter) Cooling Hose Lower End Kick Pedal Brake Pedal Muffler • Unscrew the KIPS cover bolt [A] and remove the KIPS cover [B] from the right side of the cylinder.
ENGINE RIGHT SIDE 6-11 Right Engine Cover • Set the spring [A] as shown. [B] Governor Shaft Lever [C] Exhaust Valve Shaft • Using a 14 mm open-end wrench [D], install the governor shaft lever [B] as shown. • Tighten: Torque - Governor Shaft Lever Mounting Bolt [E]: 5.9 N·m (0.60 kgf·m, 52 in·lb) NOTE...
ENGINE RIGHT SIDE 6-13 Clutch Clutch Removal • Remove the clutch cover (see Clutch Cover Removal). • Remove the clutch spring bolts [A], spring, and clutch pressure plate [B]. • Remove the push rod holder assy [A], friction plates [B], steel plates [C], and push rod.
6-14 ENGINE RIGHT SIDE Clutch Clutch Installation • Apply molybdenum disulfide grease to the outside of the sleeve. • Apply transmission oil to the inside of the clutch housing gear and kickstarter driven gear. • Install the sleeve, needle bearing, clutch hub and hous- ing.
ENGINE RIGHT SIDE 6-15 Clutch • Check the release shaft lever positions [A]. ○ Remove the magneto cover. ○ Pushing [B] the release shaft lever [C] lightly upward, measure the distance between the lever and the seating surface [D] of clutch cable, as shown. Release Shaft Lever Position 33.5 ∼...
6-16 ENGINE RIGHT SIDE Clutch Clutch Hub Spline Inspection • Visually inspect where the teeth on the steel plates wear against the splines [A] of the clutch hub. If there are notches worn into the splines, replace the clutch hub. Also, replace the clutch plates if their teeth are damaged.
ENGINE RIGHT SIDE 6-17 External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Pedal Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal) • Pull out the external shift shaft [A]. • Remove the bolts [B] and take off the shift ratchet assem- bly [C] with collar.
ENGINE RIGHT SIDE 6-19 Primary Gear Primary Gear Removal (KX250-R1) • Remove the right engine cover (see Right Engine Cover Removal) • Remove the clutch (see Clutch Removal). • Remove the circlip [A], and take off the water pump drive gear [B] and primary gear [C].
6-20 ENGINE RIGHT SIDE Primary Gear • Insert the primary gear [A] and water pump drive gear [B] to the crankshaft. • Install the washer [C] so that concave side faces inward (primary gear side). • Install the primary gear nut [D]. •...
6-22 ENGINE RIGHT SIDE Kickstarter Kickstarter Assembly Disassembly/Assembly • The kickstarter assembly consists of the following parts. • Check the kickstarter assembly parts for damage. Any damaged parts should be replaced with new ones. [A] Idle Gear [B] Circlip [C] Washer [D] Spring [E] Ratchet Gear [F] Kick Gear...
8-4 ENGINE BOTTOM END/TRANSMISSION Specifications Item Standard Service Limit Transmission Oil Grade API SE, SF or SG – – – API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 – – – Capacity 0.85 L (0.90 US qt) –...
8-6 ENGINE BOTTOM END/TRANSMISSION Transmission Oil In order for the transmission and clutch to function prop- erly, always maintain the transmission oil at the proper level and change the oil periodically. WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated transmission oil will accelerated wear and may result in transmission seizure, and injury.
ENGINE BOTTOM END/TRANSMISSION 8-7 Crankcase Crankcase Splitting • Remove the engine (see the Engine Removal/Installation chapter). • Set the engine on a clean surface while parts are being removed. • Remove: Cylinder Head (see Engine Top End chapter) Cylinder (see Engine Top End chapter) Piston (see Engine Top End chapter) Right Engine Cover (see Engine Right Side chapter) Clutch (see Engine Right Side chapter)
8-8 ENGINE BOTTOM END/TRANSMISSION Crankcase • Pull out the shift rods [A]. • Disengage the shift fork guide pins from the shift drum grooves. • Take off the shift drum [B] • Remove the shift forks [C] from the transmission gears. •...
ENGINE BOTTOM END/TRANSMISSION 8-9 Crankcase ○ Install the bearing for the shift drum so that its sealed side faces [A] inside. CAUTION Install the bearings for the crankshaft in the right and left crankcase so that their sealed sides face toward the oil seal side.
8-10 ENGINE BOTTOM END/TRANSMISSION Crankcase • Apply liquid gasket to the mating surface [A] of the crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104 -002 ○ Apply liquid gasket [B] to the outside of O-ring seating surface [C].
ENGINE BOTTOM END/TRANSMISSION 8-11 Crankcase • Remove the crankshaft jig from the flywheels. • Tighten the crankcase bolts starting with the ones around the crankshaft, and then the farther ones. ○ At this time, tighten the crankcase bolt [A] and clamp [B] for the breather hoses together.
8-12 ENGINE BOTTOM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the transmission shafts (see Transmission Shaft Removal). • Using a press, remove the crankshaft from the right crankcase. ○ If the bearings stay on the crankshaft when splitting the crankcase or removing the crankshaft from the right crankcase, remove the bearings from the crankshaft with a bearing puller [A] and adapter [B].
ENGINE BOTTOM END/TRANSMISSION 8-13 Crankshaft, Connecting Rod Connecting Rod Big End Radial Clearance • Set the crankshaft in a flywheel alignment jig or on V blocks, and place a dial gauge against the connecting rod big end. • Push the connecting rod first towards the gauge and then in the opposite direction.
8-14 ENGINE BOTTOM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Alignment • In the case of horizontal misalignment, which is the most common, strike the projecting rim of the flywheel with a plastic, soft lead, or brass hammer as indicated in the figure.
ENGINE BOTTOM END/TRANSMISSION 8-15 Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Pull off the shift rods [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.
8-16 ENGINE BOTTOM END/TRANSMISSION Transmission A. 2nd gear (23T; dog recesses face right) B. 4th gear (21T; fork groove goes to the right side of the gear teeth) C. 3rd gear (20T; dog recesses face left) D. 5th gear (20T; fork groove goes to the left side of the gear teeth) E.
ENGINE BOTTOM END/TRANSMISSION 8-17 Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. A.
8-18 ENGINE BOTTOM END/TRANSMISSION Transmission Gear Dog/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 bearing on the crankcase. Since the ball bearings are made to extremely close toler- ances, the wear must be judged by feel rather than mea- surement.
9-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 21 × 1.60 – – – Rear 19 × 2.15 – – – Rim Runout Axial TIR 1.0 mm (0.039 in.) or less TIR 2 mm (0.079 in.) Radial TIR 1.0 mm (0.039 in.) or less TIR 2 mm (0.079 in.)
9-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Using the jack [A] under the frame, and stabilize the mo- torcycle. Special Tool - Jack: 57001-1238 • Unscrew the axle nut [A]. • Loosen the left axle clamp bolts [B]. • Loosen the right axle clamp bolts [A].
WHEELS/TIRES 9-7 Wheels (Rims) • Remove the jack. • Before tightening the clamp bolts on the right fork leg, pump the forks up and down [A] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle. NOTE ○...
9-8 WHEELS/TIRES Wheels (Rims) • Remove: Disc Cover [A] Cotter Pin [B] Axle Nut [C] • Pull out the axle [D]. • Move the rear wheel back with the rear caliper installed. • Take off the collar and cap from the each side of the rear hub.
WHEELS/TIRES 9-9 Wheels (Rims) • Install the new cotter pin [A] and spread its end. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [B] up to next alignment.
9-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.937 in.) [A] apart, and set a dial gauge on the axle at a point halfway between the blocks.
WHEELS/TIRES 9-11 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter. Tires Inspection • Refer to the Tire Inspection in the Periodic Maintenance chapter. Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down.
9-12 WHEELS/TIRES Tires • Step on the side of the tire opposite valve stem, pry the tire off the rim with the tire iron [A] of the bead breaker protecting the rim with rim protectors [B]. Special Tools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 CAUTION Take care not to inset the tire irons so deeply that...
WHEELS/TIRES 9-13 Tires • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire. see Removal). • Insert the valve stem into the rim, and screw the nut on loosely.
9-14 WHEELS/TIRES Hub Bearings Hub Bearing Removal • Remove the wheel (see Wheel 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.
10-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic maintenance chapter. Wheel Alignment Inspection •...
FINAL DRIVE 10-7 Drive Chain • Install the clip [A] so that the closed end of the “U” [B] pointed in the direction of chain rotation [C]. • Adjust the drive chain slack (see Drive Chain Slack Ad- justment). • Check the rear brake (see the Brakes chapter).
11-8 BRAKES Brake Lever, Brake Pedal Brake Lever Adjustment • Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter. Brake Pedal Position Adjustment • Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter. Brake Pedal Removal •...
BRAKES 11-9 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
11-10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air.
BRAKES 11-11 Brake Fluid • Remove the clear plastic hose. • Tighten the bleed valves, and install the rubber caps. Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb) • Check the fluid level. • After bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage.
11-12 BRAKES Caliper Caliper Removal Front Brake • Loosen the banjo bolt [A] so as not to spill brake fluid. • Remove the caliper mounting bolts [B]. • Remove the banjo bolt and take off the brake hose from the caliper [C]. •...
BRAKES 11-13 Caliper Caliper Installation • Tighten the brake pad bolts if it was removed. Torque - Brake Pad Bolts: 18 N·m (1.8 kgf·m, 13 ft·lb) Front Brake: • Install the caliper and tighten the bolts. Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18.0 ft·lb) Rear Brake: •...
11-14 BRAKES Caliper Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
BRAKES 11-15 Caliper Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. • Install the piston side pad first, and then another pad. ○ Fit the pad end [A] into the groove [B] of the anti-rattle spring securely.
Unscrew the clamp bolts [B], and take off the master cylin- der [C] as an assembly with the reservoir and brake lever. Front Master Cylinder Installation KX250-R1: • Position the master cylinder so that the vertical parting line [A] of the front master cylinder clamps align with the punch mark [B] on the handlebar.
BRAKES 11-17 Master Cylinder Rear Master Cylinder Removal • Remove the cotter pin [A]. • Pull off the joint pin [B] with washer. NOTE ○ Pull off the joint pin while pressing down the brake pedal. • Unscrew the master cylinder mounting bolts [C], and re- move the master cylinder [D].
11-18 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B].
BRAKES 11-19 Brake Disk Brake Disc Inspection • Visually inspect the disc [A]. If it is scratched or damaged, replace the disc. • Measure the thickness of each disc at the point [B] where it has worn the most. Replace the disc if it has worn past the service limit. Thickness Standard: 2.85 ∼...
11-20 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose and Connection Check in the Periodic Maintenance chapter.
SUSPENSION 12-1 Suspension Table of Contents Exploded View........12-2 Rear Shock Absorber Installation 12-27 Specifications ........12-6 Spring Replacement ....12-27 Special Tools ........12-8 Rear Shock Absorber Front Fork .......... 12-9 Disassembly (Oil Change) ..12-28 Air Pressure ......... 12-9 Rear Shock Absorber Assembly ..
26. Steering Stem Head 27. Steering Stem AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent to the threads. R: Replacement Parts A: KX250-R1 Model B: KX250-R1, R6F C: KX250R7F...
The left and right fork legs must have the same shock damping. Seated positions: adjuster turned fully clockwise [A]. Compression Damping Adjuster Setting Standard: KX250-R1 10 clicks [B] KX250R6F ∼ 11 clicks Softer (Counterclockwise) [C] Harder (Clockwise) [D] *: Number of turns counterclockwise usable range-16 clicks or more.
The left and right fork legs must have the same shock damping. Seated positions adjuster turned fully clockwise [A]. Rebound Damping Adjuster Setting Standard: KX250-R1 12 clicks [B] KX250R6F ∼ 11 clicks Softer (Counterclockwise) [C] Harder (Clockwise) [D] *: Number of turns counterclockwise usable range-16 clicks or more.
Loosen the upper [A], and lower [B] fork clamp bolts. • Remove the front fork. ○ With a twisting motion [A], work the fork leg [B] down and out. • Remove: Bolts [A] Fork Protector [B] Guide [C] (KX250-R1, R6F) Bolt [D] (KX250-R1, R6F)
12-12 SUSPENSION Front Fork Front Fork Installation • Install the fork so that the distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension. [A] = 4 mm (0.16 in.) •...
SUSPENSION 12-13 Front Fork • Using the special tool [A], remove the fork top plug [B] (subtank) from the outer tube and slowly slide down the outer tube [C]. Special Tool - Top Plug Wrench, 46 mm: 57001-1622 • Place a drain pan under the front fork and drain fork oil [A].
Special Tool - Top Plug Wrench, 46 mm: 57001-1622 [B] • Remove: Cylinder Unit [A] Spring Collar [B] (KX250-R1) Fork Spring [C] Spring Collar [D] CAUTION Disassembling the cylinder unit can lead to trouble. Do not disassemble the cylinder unit.
SUSPENSION 12-15 Front Fork • Remove the dust seal [A] and the retaining ring [B]. CAUTION Be careful not to scratch the inner tube. • Grasp the outer tube and stroke [A] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube.
12-16 SUSPENSION Front Fork • Drain the fork oil [A] from the cylinder unit [B] by pumping the piston rod several times Front Fork Assembly • When the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain.
SUSPENSION 12-17 Front Fork • Clean the threads [A] of subtank and base valve assem- bly. • With the piston rod in fully compressed position, pour the specified amount of fork oil [A]. Recommended Oil: KHL15-10 (KAYABA01) or equivalent Recommended Quantity: 160 ml (5.41 US oz) NOTE ○...
12-18 SUSPENSION Front Fork • With the piston rod held immorable in fully compressed position [A], gently install the base valve assembly [B] to the subtank. • Screw in the base valve assembly in the subtank when the piston rod extends. NOTE ○...
Make sure about 16 mm (0.63 in.) [A] of push rod thread is exposed from the lock nut [B]. • Completely wipe of the fork oil from following parts. Cylinder Unit [A] Spring Collar [B] (KX250-R1) Spring [C] Spring Collar [D] • Insert above-mentioned parts into the fork.
12-20 SUSPENSION Front Fork • Clamp the axle holder with a vise. ○ Protect the axle holder with a rag when using a vise. WARNING Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight. •...
Pour [A] the specified amount of fork oil into the outer tube. Recommended Oil: KHL15-10 (KAYABA01) or equivalent Recommended Quantity: KX250-R1 300 mL (10.14 US oz) KX250R6F ∼ 310 mL (10.48 US oz) • Raise the outer tube and temporarily tighten the fork top plug (subtank).
12-22 SUSPENSION Front Fork Adjuster Assembly Inspection • Inspect the adjuster assembly [A] and push rod [B] for damage. If they are damaged, replace them with new ones. • Replace the gasket [C] and O-ring [D] on the adjuster as- sembly with new ones.
SUSPENSION 12-23 Front Fork Guide Bush Inspection • Visually inspect the guide bushes [A], and replace them if necessary. Dust Seal/Oil Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary. •...
If the damper setting feels too soft or too stiff, adjust it in accordance with the following table: Seated position: adjuster turned fully clockwise [A]. Rebound Damping Adjuster Setting Standard: KX250-R1 9 clicks [B] KX250R6F ∼ 10 clicks Softer (Counterclockwise) [C] Harder (Clockwise) [D] *: Number of turns counterclockwise usable range-16 clicks or more.
SUSPENSION 12-25 Rear Suspension (Uni-Trak) Compression Damping Adjustment KX250-R1 • Turn the compression damping adjuster [A] on the rear shock absorber gas reservoir with a flat-blade screw- driver. KX250R6F ∼ There are two adjustments you can make to the rear shock absorber gas reservoir.
Special Tool - Steering Stem Nut Wrench: 57001-1100 Spring Preload Adjustment (Adjusting nut position at the lower surface [A] from the center of the mounting hole) Standard: KX250-R1 120 mm (4.72 in.) KX250R6F ∼ 118 mm (4.65 in.) Adjustable Range: 109 ∼ 129.5 mm (4.29 ∼ 5.10 in.) •...
SUSPENSION 12-27 Rear Suspension (Uni-Trak) Spring Tension • Since the spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring is shorter than the service limit, it must be replaced. Shock Absorber Spring Free Length Standard: 260 mm (10.24 in.) Service Limit: 255 mm (10.04 in.)
12-28 SUSPENSION Rear Suspension (Uni-Trak) • Using the hook wrenches [C], loosen the locknut [B] and turn the adjusting nut [A] all way up. Special Tool - Hook Wrench R37.5, R42: 57001-1101 • Remove the rear shock absorber from the vise. •...
SUSPENSION 12-29 Swingarm Swingarm Removal • Remove: Bolts [A] Chain Guide Plate [B] Chain Guide [C] • Place the jack [A] under the frame so that the rear wheel is off the ground. Special Tool - Jack: 57001-1238 • Remove Rear Wheel (see Wheels/Tires chapter) Clamps [B] Brake Pedal [C] (see Brakes chapter)
SUSPENSION 12-31 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 • Unscrew the nut [A] and remove the guide roller [B]. CAUTION When pulling out the mounting bolts, lift the rear wheel slightly.
12-32 SUSPENSION Tie-rod, Rocker Arm • Remove the rocker arm pivot shaft [A]. • Remove the rocker arm [B]. Rocker Arm Installation • Apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve.
SUSPENSION 12-33 Tie-rod, Rocker Arm • Install the needle bearings [A], [B], grease seals [C], and oil seals [D] position as shown. ○ The installation procedure is the same as the counter side. 1. 1.5 mm (0.0591 in.) 2. 4.5 mm (0.1772 in.) 3.
12-34 SUSPENSION Uni-Trak Maintenance Uni-Trak Linkage Inspection • Refer to the Uni-Trak Linkage Inspection in the Periodic Maintenance chapter. Tie-rod and Rocker Arm Sleeve Wear • Pull out the sleeves [A] of the tie-rod and rocker arm. • Measure the outside diameter of the sleeve. If the sleeve is worn past the service limit, replace the sleeve.
AL: Tighten the clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. O: Apply 2 Stroke Oil. T: Tighten all snugly, then loosen, retighten to 4.9 N·m (0.5 kgf·m, 43 in·lb). A: KX250-R1 Model B: KX250R6F Model ∼...
Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter. Steering Stem, Stem Bearing Removal KX250-R1: • Remove: Front Wheel (see Wheels/Tires chapter) Number Plate [A] Handlebar Holder Bolts [B] Handlebar Holder (Upper) [C] Handlebar [D] (see Handlebar Removal) •...
13-6 STEERING Steering • Pushing up on the stem base [A], and remove the steering stem nut [B], with the steering stem nut wrench [C], then remove the steering stem [D] and stem base. Special Tool - Steering Stem Nut Wrench: 57001-1100 •...
STEERING 13-7 Steering Steering Stem, Stem Bearing Installation • Replace the bearing outer race with new ones. ○ Apply grease to the outer races, and drive them into the head pipe at the same time using the head pipe outer race press shaft [A] and the drivers.
13-8 STEERING Steering • Install the front fork (see the Suspension chapter). NOTE ○ Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolt. Torque - Steering Stem Head Nut: 98 N·m (10.0 kgf·m, 72 ft·lb) Front Fork Clamp Bolts (Upper, Lower): 20 N·m (2.0 kgf·m, 14.5 ft·lb)
STEERING 13-9 Steering Maintenance Stem Bearing Lubrication • Refer to the Stem Bearing Lubrication in the Periodic Maintenance chapter. Stem Bearing Wear, Damage • 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.
• Remove: Handlebar Holder Bolts [A] Handlebar Holders (Upper) [B] Handlebar [C] Handlebar Installation (KX250-R1) • Apply adhesive cement to the inside of the left handlebar grip. • Install the left handlebar grip so that the arrow [A] on the grip point to the punch mark [B] on the handlebar.
13-12 STEERING Handlebar • Install the handlebar [A] on the handlebar holder as shown. Same Length [B] Bridge Bar [C] • Install the handlebar holder (see Steering Adjustment in the Periodic Maintenance chapter). ○ Mount the handlebar holder [A] so that the marks [B] on the clamp points toward rear.
STEERING 13-13 Handlebar • Install the handlebar [A] on the handlebar holder as shown. Same Length [B] Bridge Bar [C] Protrusion of Graduation [D] • Install the handlebar holders upeer. [A] with handlebar. ○ Tighten the front and rear bolts [B] of the handlebar clamps equally.
14-4 FRAME Frame Frame Inspection • Refer to the Frame Inspection in the Periodic Mainte- nance chapter. Rear Frame Removal • Remove: Seat (see Seat Removal) Right & Left Side Cover (see Side Cover Removal) Muffler (see Engine Top End chapter) Rear Fender (see Fender Removal) Rear Flap (see Flap Removal) •...
FRAME 14-7 Fender Front Fender Removal • Unscrew the bolts [A] and remove the front fender [B]. Rear Fender Removal • Remove: Seat (see this chapter) Side Covers (see this chapter) • Unscrew the bolts [A] and remove the rear fender [B]. Rear Fender Installation •...
ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Exploded View........................15-2 Wiring Diagram........................15-4 Specifications ......................... 15-5 Special Tools .......................... 15-6 Precautions..........................15-7 Electrical Wiring........................15-8 Wiring Inspection ......................15-8 Ignition Timing ........................15-9 Ignition Timing Adjustment....................15-9 Flywheel Magneto ........................15-10 Flywheel Magneto Removal....................
ELECTRICAL SYSTEM 15-7 Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ The 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.
15-8 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
ELECTRICAL SYSTEM 15-9 Ignition Timing Ignition Timing Adjustment • Remove the magneto cover. • Check to see if the center mark of the three marks [A] on the magneto stator is aligned with the mark [B] on the crankcase. If the marks are not aligned, loosen the magneto stator screws [C] and turn the magneto stator [D].
15-10 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Magneto Removal • Remove the magneto cover. • Hold the flywheel steady, with the flywheel holder [A], and remove the flywheel nut [B]. Special Tool - Flywheel & Pulley Holder: 57001-1605 • Remove the flywheel holder. •...
15-12 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Magneto Inspection • There are three types of magneto problems: short, open (wire burned out), or loss in flywheel magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
ELECTRICAL SYSTEM 15-13 Flywheel Magneto If there is more resistance than shown in the table, or no hand tester reading (infinity) the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. •...
15-14 ELECTRICAL SYSTEM Ignition System Safety Instructions WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil, or high tension lead while the engine is running, or you could receive a severe electrical shock. Ignition Coil Removal •...
ELECTRICAL SYSTEM 15-15 Ignition System Measuring Coil Resistance If the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.
15-16 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Check • Disconnect the spark plug cap from mounting the spark plug. • Connect the good spark plug [A] to the spark plug cap, then touch the engine with the spark plug. NOTE ○...
ELECTRICAL SYSTEM 15-17 Ignition System...
15-18 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Check • To check the peak voltage, do the following procedures. ○ Disconnect the connector of the magneto lead connector from the main harness. NOTE ○ Measure the voltage with each lead connected cor- rectly.
ELECTRICAL SYSTEM 15-19 Ignition System Exciter Coil Peak Voltage Check • Disconnect the connector of the magneto lead connector from the main harness. • To check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor- rectly.
15-20 ELECTRICAL SYSTEM Ignition System Throttle Sensor Output/Input Voltage Check NOTE ○ If the variable rheostat is available, refer to throttle sen- sor inspection. • Remove the carburetor lead connector. • Connect the needle adapter set [A] to the carburetor lead connector [B].
Loosen the crankshaft sensor screws [A]. • Insert a thickness gauge [B] between the crankshaft sen- sor core and the timing plate. Thickness Gauge: 0.65 mm (0.026 in.) KX250-R1, R6F 0.85 mm (0.033 in.) KX250R7F • While pressing the crankshaft sensor toward the magneto flywheel, tighten the coil screws and remove the thickness gauge.
15-22 ELECTRICAL SYSTEM Throttle Sensor Throttle Sensor Inspection NOTE ○ If the variable rheostat is not available, refer to throttle sensor output/input voltage check in the C.D.I Unit in- spection. ○ When inspecting the throttle sensor the throttle valve of the carburetor shall be completely closed and remain the throttle cable connected.
ELECTRICAL SYSTEM 15-23 Fuel Cut Valve Fuel Cut Valve Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
APPENDIX 16-1 Appendix Table of Contents Troubleshooting Guide ......................16-2 Cable, Wire and Hose Routing ....................16-6...
16-2 APPENDIX Troubleshooting Guide NOTE Piston ring/groove clearance excessive ○ This is not an exhaustive list, giving every Cylinder head gasket damaged possible cause for each problem listed. It Cylinder head warped is meant simply as a rough guide to assist Cylinder base gasket damaged the troubleshooting for some of the more Read valve damaged...
APPENDIX 16-3 Troubleshooting Guide Poor Running or No Power at High Transmission oil viscosity too high Speed Crankshaft bearing worn or damaged Firing incorrect KIPS ports stuck closed Spark plug dirty, damaged, or maladjusted KIPS ports stuck closed Spark plug cap or high tension wiring dam- KIPS exhaust valves stuck closed (valve aged seizure, or carbon accumulation)
16-4 APPENDIX Troubleshooting Guide Clutch plate warped or too rough Crankshaft runout excessive Clutch spring tension uneven Engine mounts loose Transmission oil deteriorated Crankshaft bearing worn Transmission viscosity too high Primary gear worn or chipped Transmission oil level too high Abnormal Drive Train Noise Clutch housing frozen on drive shaft Clutch release mechanism trouble...
APPENDIX 16-5 Troubleshooting Guide Handling and/or Stability Right/left front fork oil level uneven Unsatisfactory Shock absorption unsatisfactory Handlebar hard to turn (Too hard) Control Cable routing incorrect Front fork oil excessive Wiring routing incorrect Front fork oil viscosity too high Steering stem nut too tight Front fork leg bent Bearing ball damaged...
16-6 APPENDIX Cable, Wire and Hose Routing...
7. Carburetor Leads 8. Carburetor Leads Connector 9. Main Harness 10. Do not slacken. 11. Clamp the main harness as shown. 12. Band 13. Run the clutch cable above the number plate mounting bracket. A: KX250-R1 Model B: KX250R6F Model ∼...
16-8 APPENDIX Cable, Wire and Hose Routing...
APPENDIX 16-9 Cable, Wire and Hose Routing 1. To Engine Stop Switch 2. CDI Unit 3. Do not slacken. 4. Clamp the throttle cable, CDI unit leads and engine stop switch leads. 5. To Ignition Coil 6. Clamp the throttle cable. Be careful not to bite cable when installing the fuel tank. Run the main harness under the frame.
16-10 APPENDIX Cable, Wire and Hose Routing...
APPENDIX 16-11 Cable, Wire and Hose Routing 1. Clutch Cable 2. Clamp 3. Main Harness Ground Lead (Outside) 4. Ignition Coil Ground Lead (Inside) 5. Ignition Coil 6. Tighten together with the main harness ground lead and ignition coil ground lead with the ignition coil mounting bolt.
16-12 APPENDIX Cable, Wire and Hose Routing...
APPENDIX 16-13 Cable, Wire and Hose Routing 1. Front Brake Reservoir 2. Banjo Bolts 3. Clamp 4. Clamp Brackets 5. Front Brake Disc 6. Front Fork Guard 7. Bleed Valves 8. Front Brake Caliper 9. Rear Brake Caliper 10. Caliper Guard 11.
MODEL APPLICATION Year Model Beginning Frame No. □ JKAKXMRC 5A000001 or 2005 KX250-R1 JKAKX250RRA000001 □ JKAKXMRC 6A006001 or 2006 KX250R6F JKAKX250RRA006001 □ JKAKXMRC 7A010001 or 2007 KX250R7F JKAKX250RRA010001 □ JKAKXMRC 8A013001 or 2008 KX250R8F JKAKX250RRA013001 □ :This digit in the frame number changes from one machine to another.