Kawasaki KX250F - Service Manual / Repair Manual - Wiring Diagrams - Owners Manual

KAWASAKI KX250F - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual / Repair Manual, Wiring Diagrams and Owners Manual, for motorcycles Kawasaki KX250F.

 
CONTENTS:

- 2004 SERVICE MANUAL
- 2006 SERVICE MANUAL
- 2008 OWNERS MANUAL
- 2010 SERVICE MANUAL
- 2011 OWNERS MANUAL
- 2011-2012 SERVICE MANUAL
- 2013-2014 SERVICE MANUAL


INDEX SERVICE MANUAL

- Units of Mass:
- Units of Volume:
- Units of Force:
- Units of Length:
- Units of Torque:
- Units of Pressure:
- Units of Speed:
- Units of Power:
- Basic Torque for General Fasteners
- Throttle Grip Free Play
- Hot Start Lever Free Play
- Idle Speed:
- Valve clearance: between cam and valve lifter
- Adjustment shims
- Cylinder Head Warp
- Cylinder Inside Diameter
- Piston/Cylinder Clearance
- Clutch Lever Free Play
- Friction Plate Thickness
- Steel Plate Thickness
- Friction and Steel Plates Warp
- Recommended Engine
- Connecting Rod Big End Radial Clearance
- Connecting Rod Big End Side Clearance
- Standard Tire
- Rim Runout (with tire installed)
- Chain 20-link Length
- Standard Chain
- Engine Sprocket Diameter
- Rear Sprocket Diameter
- Rear Sprocket Warp
- Length [A]
- Recommended Disc Brake Fluid
- Lining Thickness
- Recommended Oil
- Oil Level (fully compressed, without spring)
- Spark Plug Gap
- Service Fuel Level (above the bottom edge of the carb. body)
- Float Height
- Recommended Coolant
- Radiator Cap Relief Pressure:
- Camshaft Bearing Clearance
- Camshaft Journal Diameter
- Cylinder Compression
- Valve/Valve Guide Clearance Measurement-Wobble Method
- Valve Seating Surface Outside Diameter
- Valve Seating Surface Width Standard
- Piston Diameter
- Piston Ring/Ring Groove Clearance
- Piston Ring Groove Width
- Piston Ring Thickness (Top)
- Piston Ring End Gap
- Piston Pin Diameter
- Piston Pin Hole Diameter
- Small End Inside Diameter
- Release Shaft Lever Position
- Adjusting Washers
- Release Shaft Lever Position and Adjusting Washer Selection
- Clutch Spring Free Length
- Friction Plate/Clutch Housing Clearance
- Oil Pump Pressure (oil temperature 90°C, @4 000 rpm)
- Connecting Rod Bend
- Connecting Rod Twist
- Axle Runout/100 mm (3.937 in.)
- Chain Slack
- Thickness
- Runout
- Rebound Damping Adjuster Setting
- Compression Damping Adjuster Setting
- Front Fork Oil Level (fully compressed, without spring)
- Fork Spring Free Length
- Rebound Damping Adjuster Setting
- Rebound Damping Adjuster Setting
- Spring Preload Adjustment
- Shock Absorber Spring Free Length
- Sleeve Outside Diameter
- Bolt Runout
- Table 1 Magneto Output Voltage
- Table 2 Stator Coil Resistance
- Ignition Timing
- 3 Needle Arcing Distance
- Ignition Coil Winding Resistance
- Throttle Sensor Input Voltage
- Throttle Sensor Output Voltage
- Throttle Sensor Input Voltage
- Throttle Sensor Output Voltage
- Throttle sensor Output Voltage
- Throttle Sensor Output Voltage
- toc
- Foreword
- General Information
- Before starting to perform an inspection service or carry out a
- Edges of Parts
- Solvent
- Cleaning vehicle before disassembly
- Arrangement and Cleaning of Removed Parts
- Storage of Removed Parts
- Inspection
- Replacement Parts
- Assembly Order
- Tightening Sequence
- Tightening Torque
- Force
- Gasket, O‐ring
- Liquid Gasket, Locking Agent
- Press
- Ball Bearing and Needle Bearing
- Oil Seal, Grease Seal
- Circlips, Cotter Pins
- Lubrication
- Direction of Engine Rotation
- Electrical Wires
- KX250–N1 Left Side View
- KX250–N1 Right Side View
- Prefixes for Units:
- Units of Temperature:
- Periodic Maintenance
- The maintenance must be done in accordance with this chart to ke
- Tighten all bolts and nuts to the proper torque using an accurat
- Valve Spring Compressor Assembly :
- Fuel System
- Fuel Hose and Connection Inspection
- Throttle Grip Free Play Inspection
- Throttle Grip Free Play Adjustment
- Hot Start Lever Free Play Inspection
- Idle Speed Inspection
- Idle Speed Adjustment
- Air Cleaner Element Cleaning and Inspection
- Cooling System
- Engine Top End
- Engine Right Side
- Engine Lubrication System
- Crankshaft/Transmission
- Wheel/Tires
- Final Drive
- Brakes
- Suspension
- Steering
- Frame
- Electrical System
- Cable Inspection
- Nut, Bolt, and Fastener Tightness Inspection
- Fuel System
- Fuel Level Gauge, M18 × 1.0 :
- If the throttle grip has excessive free play due to cable stretc
- Free Play Inspection
- Free Play Adjustment
- Throttle Cable Replacement
- Throttle Cable Lubrication
- Throttle Cable Inspection
- Hot Start Cable Removal
- Hot Start Cable Installation
- Hot Start Lever Free Play Inspection
- Hot Start Lever Free Play Adjustment
- Hot Start Cable Lubrication
- Hot Start Cable Inspection
- Since the carburetor regulates and mixes the fuel and air going
- Idle Speed Inspection
- Idle Speed Adjustment
- Service Fuel Level Inspection
- Service Fuel Level Adjustment
- Carburetor Removal
- Carburetor Installation
- Fuel Inspection
- Carburetor Disassembly
- Carburetor Cleaning
- Carburetor Inspection
- Carburetor Assembly
- Air Cleaner Housing Removal
- Air Cleaner Housing Installation
- Element Removal
- Element Installation
- Element Cleaning and Inspection
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tap Removal
- Fuel Tap Installation
- Fuel Tank and Tap Cleaning
- Fuel Tap Inspection
- Cooling System
- Bearing Driver Set :
- Check the coolant level each day before riding the motorcycle, a
- Coolant Level Inspection
- Coolant Deterioration Inspection
- Coolant Draining
- Coolant Filling
- Air Bleeding
- Cooling System Pressure Testing
- Cooling System Flushing
- Water Pump Cover Removal
- Water Pump Cover Installation
- Impeller Removal
- Impeller Installation
- Water Pump Inspection
- Water Pump Gear Removal
- Water Pump Gear Installation
- Oil Seal and Bearing Removal
- Oil Seal Installation
- Radiator Removal
- Radiator Installation
- Radiator Inspection
- Radiator Cap Inspection
- Filler Neck Inspection
- Radiator Hoses, Breather Hose Inspection
- Radiator Hoses, Breather Hose Installation
- Engine Top End
- Cam Height
- Camshaft Runout
- Valve Stem Diameter
- Valve Stem Bend
- Compression Gauge, 20 kgf/cm :
- Cylinder Head Cover Removal
- Cylinder Head Cover Installation
- Camshaft Chain Tensioner Removal
- Camshaft Chain Tensioner Installation
- Camshaft Removal
- Camshaft Installation
- Camshaft and Camshaft Cap Wear
- Camshaft Chain Removal
- Camshaft Chain Installation
- Cylinder Compression Measurement
- Special Tool -
- Owner's Tool -
- Special Tool -
- Torque -
- Cylinder Head Removal
- Cylinder Head Installation
- Cylinder Head Cleaning
- Cylinder Head Warp
- Valve Clearance Inspection
- Valve Removal
- Valve Installation
- Valve Guide Removal
- Valve Guide Installation
- Valve/Valve Guide Clearance Measurement (Wobble Method)
- Valve Seat Inspection
- Valve Seat Repair
- Valve Seat Repair
- Cylinder Removal
- Piston Removal
- Cylinder and Piston Installation
- Cylinder Wear
- Piston Wear
- Piston/Cylinder Clearance
- Piston Ring/Ring Groove Clearance
- Piston Ring Groove Width
- Piston Ring Thickness
- Piston Ring End Gap Measurement
- Piston, Piston Pin, Connecting Rod Wear Inspection
- Carburetor Holder Installation
- Torque -
- WARNING
- Muffler Removal
- Muffler Installation
- Engine Right Side
- Clutch Holder :
- Due to friction plate wear and clutch cable stretch over a long
- Clutch Lever Free Play Inspection
- Clutch Lever Free Play Adjustment
- Clutch Lever Installation
- Clutch Cable Removal
- Clutch Cable Installation
- Clutch Cable Inspection and Lubrication
- Clutch Cover Removal
- Clutch Cover Installation
- Right Engine Cover Removal
- Right Engine Cover Installation
- Release Shaft Removal
- Release Shaft Installation
- Clutch Removal
- Special Tools -
- Clutch Installation
- Friction and Steel Plates Wear, Damage Inspection
- Friction and Steel Plate Warp Inspection
- Clutch Spring Free Length Inspection
- Clutch Housing Finger Damage
- Friction Plate/Clutch Housing Clearance
- Clutch Hub Spline Damage
- Primary Gear Removal
- Special Tool -
- Primary Gear Installation
- External Shift Mechanism Removal
- External Shift Mechanism Installation
- External Shift Mechanism Inspection
- Kick Pedal Assy Removal
- Kick Pedal Assy Installation
- Kick Pedal Assy Disassembly
- Kick Pedal Assy Assembly
- Idle Gear Removal
- Idle Gear Installation
- Kickshaft Removal
- Kickshaft Installation
- Kickstarter Assembly Disassembly/Assembly
- Engine Lubrication System
- Oil Pressure Gauge, 5 kgf/cm :
- WARNING
- Engine Oil Level Inspection
- Engine Oil Change
- Oil Filter Change
- Oil Screen Removal
- Oil Screen Installation
- Oil Pump Removal
- Special Tool -
- Special Tool -
- Oil Pump Installation
- Oil Pump Inspection
- Oil Pressure Measurement
- Special Tools -
- Engine Removal/Installation
- Jack:
- Engine Removal
- Special Tool -
- Engine Installation
- Crankshaft/Transmission
- Bearing Puller :
- Crankcase Disassembly
- Special Tool -
- Special Tool -
- Crankcase Assembly
- Crankshaft Removal
- Special Tools -
- Crankshaft Installation
- Crankshaft Disassembly
- Crankshaft Assembly
- Connecting Rod Bend
- Connecting Rod Twist
- Transmission Shaft Removal
- Transmission Shaft Installation
- Transmission Shaft Disassembly
- Transmission Shaft Assembly
- Shift Fork Bending
- Shift Fork/Gear Groove Wear
- Shift Fork Guide Pin/Shift Drum Groove Wear
- Gear Damage
- Bearing Replacement
- Special Tool -
- Bearing Inspection
- Oil Seal Inspection
- Wheels/Tires
- Inside Circlip Pliers :
- Front Wheel Removal
- Special Tools -
- Front Wheel Installation
- Rear Wheel Removal
- Rear Wheel Installation
- Wheels Inspection
- Spoke Tightness Inspection
- Rim Runout Inspection
- Axle Inspection
- Tire Removal
- Special Tools -
- Special Tools -
- Installation
- Hub Bearing Removal
- Special Tool -
- Hub Bearing Installation
- Hub Bearing Inspection
- Final Drive
- Outside Circlip Pliers :
- Drive Chain Slack Inspection
- Drive Chain Slack Adjustment
- Wheel Alignment Inspection
- Wheel Alignment Adjustment
- Drive Chain Wear Inspection
- Drive Chain Lubrication
- Drive Chain Removal
- Drive Chain Installation
- Engine Sprocket Removal
- Special Tools -
- Engine Sprocket Installation
- Rear Sprocket Removal
- Rear Sprocket Installation
- Sprocket Wear Inspection
- Rear Sprocket Warp Inspection
- Brakes
- Inside Circlip Pliers :
- Brake Lever Play Adjustment
- Brake Pedal Position/Pedal Play Adjustment
- Brake Pedal Removal
- Brake Pedal Installation
- WARNING
- Fluid Level Inspection
- Fluid Change
- Bleeding the Brake Line
- Caliper Removal
- Caliper Installation
- Caliper Disassembly
- Fluid Seal Damage
- Dust Seal and Cover Damage
- Piston Cylinder Damage
- Caliper Holder Shaft Wear
- Brake Pad Removal
- Brake Pad Installation
- Brake Pad Inspection
- CAUTION
- Front Master Cylinder Removal
- Front Master Cylinder Installation
- Rear Master Cylinder Removal
- Rear Master Cylinder Installation
- Front Master Cylinder Disassembly
- Rear Master Cylinder Disassembly
- Master Cylinder Assembly
- Master Cylinder Inspection (Visual Inspection)
- Brake Disc Inspection
- Special Tool -
- Brake Hose Removal/Installation
- Brake Hose Inspection
- Suspension
- Oil Seal & Bearing Remover :
- Air Pressure
- Special Tool -
- Rebound Damping Adjustment
- Compression Damping Adjustment
- Fork Oil Level Adjustment (Simplify)
- Oil Change/Oil Level Adjustment (each fork leg)
- Front Fork Removal
- Front Fork Installation
- Front Fork Disassembly (each fork leg)
- Front Fork Assembly
- Inner Tube Inspection
- Guide Bush Inspection
- Dust Seal/Oil Seal Inspection
- Spring Tension
- Rear Shock Absorber:
- Rebound Damping Adjustment
- Compression Damping Adjustment
- Spring Preload Adjustment
- Spring Tension
- Rear Shock Absorber Removal
- Rear Shock Absorber Installation
- Spring Replacement
- Rear Shock Absorber Disassembly (Oil Change)
- Rear Shock Absorber Assembly
- Rear Shock Absorber Scrapping
- Swingarm Removal
- Special Tool -
- Swingarm Installation
- Swingarm Bearing Removal
- Swingarm Bearing Installation
- Drive Chain Guide, Guide Roller, Chain Slipper Wear
- Swingarm Bearing, Sleeve Inspection
- Tie-Rod Removal
- Special Tool -
- Tie-Rod Installation
- Rocker Arm Removal
- Rocker Arm Installation
- Tie-Rod and Rocker Arm Bearing Removal
- Tie-Rod and Rocker Arm Bearing Installation
- Needle Bearing Inspection
- Uni-Trak Linkage Inspection
- Tie-Rod and Rocker Arm Sleeve Wear
- Tie-Rod and Rocker Arm Mounting Bolt Bend
- Steering
- Bearing Puller :
- Steering Inspection
- Steering Adjustment
- Steering Stem, Stem Bearing Removal
- Steering Stem, Stem Bearing Installation
- Stem Bearing Lubrication
- Stem Bearing Wear, Damage
- Stem Warp
- Handlebar Removal
- Handlebar Installation
- Frame
- Frame Inspection
- Rear Frame Removal
- Rear Frame Installation
- Engine Guard Installation
- Seat Removal
- Seat Installation
- Side Cover Removal
- Side Cover Installation
- Front Fender Removal
- Rear Fender Removal
- Rear Flap Removal
- Electrical System
- Timing Light :
- There are numbers of important precautions that are musts when s
- Wiring Inspection
- Magneto Cover Removal
- Magneto Cover Installation
- Flywheel Magneto Removal
- Flywheel Magneto Installation
- Stator Removal
- Stator Installation
- Flywheel Magneto Inspection
- Ignition Timing Inspection
- Special Tool -
- Torque -
- Safety Instructions:
- Ignition Coil Removal
- Ignition Coil Inspection
- Spark Plug Cleaning and Inspection
- Spark Plug Gap Inspection
- C.D.I Unit Removal
- C.D.I Unit Inspection
- Throttle Sensor Output/Input Voltage Check
- Engine Stop Switch Electric Current Check:
- Crankshaft Sensor Inspection
- Throttle Sensor Inspection
- Throttle Sensor Position Adjustment
- Neutral Switch Inspection
- Special Tool -
- Neutral Switch Connections
- Appendix
- This is not an exhaustive list, giving every possible cause for
- Engine Doesn't Start, Starting Difficulty:
- Poor Running at Low Speed:
- Poor Running or No Power at High Speed:
- Engine Overheating:
- Clutch Operation Faulty:
- Gear Shifting Faulty:
- Abnormal Engine Noise:
- Abnormal Drive Train Noise:
- Abnormal Frame Noise:
- Abnormal Exhaust Color:
- Handling and/or Stability Unsatisfactory:
- Brake Doesn't Hold:


INDEX OWNERS MANUAL
- Specifications
- General Information
- Location of Labels
- Location of Parts
- Side Stand
- Fuel
- Kick Pedal
- Starting the Engine
- Launch Control Mode
- DFI Setting Data Selection
- Shifting Gears
- Stopping the Motorcycle
- Stopping the Engine
- Break-In
- Daily Pre-Ride Checks
- After-Race Checks
- Maintenance And Adjustment
- Periodic Maintenance Chart
- Engine Oil
- Cooling System
- Spark Plug
- Air Cleaner
- Throttle Cable
- Throttle Body Assy
- Clutch
- Valve Clearance
- Exhaust System
- Drive Chain
- Handlebars
- Brakes
- Steering
- Front Suspension
- Rear Suspension (UNI-TRAK®)
- Wheels
- Hoses Inspection
- Tightening Torques of Nuts and Bolts
- Cleaning Your Motorcycle
- Lubrication
- DFI Self-Diagnosis
- Troubleshooting Guide
- Tuning
- Suspension
- Gearing
- Special Care According to Track Conditions
- Optional Parts
- Pre-Race Checks And After-Race Maintenance
- Storage
- Before Storage
- After Storage
- Environmental Protection
- Wiring Diagram