2010 Kawasaki KX250F Owners Manual

2010 Kawasaki KX250F Manual

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  • 2010 Kawasaki KX250F | Owners Manual - Page 1
  • 2010 Kawasaki KX250F | Owners Manual - Page 2
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING GUIDE TUNING STORAGE j j j j j A Table of Contents is included after the Foreword.
  • 2010 Kawasaki KX250F | Owners Manual - Page 3
    limited to participation in sanctioned competition events upon a closed • The course. vehicle should not be used for general off-road recreational riding. • This Read owner's manual. •
  • 2010 Kawasaki KX250F | Owners Manual - Page 4
  • 2010 Kawasaki KX250F | Owners Manual - Page 5
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER DANGER
  • 2010 Kawasaki KX250F | Owners Manual - Page 6
    FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. Motorcycle Noise Emission Control Information This motorcycle is designed sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your service and/or necessary repairs.
  • 2010 Kawasaki KX250F | Owners Manual - Page 7
    tuned competition machine for participation in racing events. As with any mechanical device, proper care and maintenance are important for trouble-free operation and top performance. This manual is written to enable you to keep your KX properly tuned and adjusted. Due to improvements in design and
  • 2010 Kawasaki KX250F | Owners Manual - Page 8
    Rear Suspension (UNI-TRAK®)...Wheels ...Hoses Inspection ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor ...Suspension...Gearing...Special Care According to Track Conditions . OPTIONAL PARTS ...PRE-RACE CHECKS AND AFTER
  • 2010 Kawasaki KX250F | Owners Manual - Page 9
    8 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing Lubrication System Spark Plug Spark Plug
  • 2010 Kawasaki KX250F | Owners Manual - Page 10
    SPECIFICATIONS 9 TRANSMISSION Transmission Type Clutch Type Driving System Gear Ratio: 1st 2nd 3rd 4th 5th Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Engine Oil: Type Viscosity Capacity FRAME Type Steering Angle Caster Trail Tubular, semi-double cradle 42° to either side 27.4°
  • 2010 Kawasaki KX250F | Owners Manual - Page 11
    10 SPECIFICATIONS Tire Size/Type: Front Rear Rim Size: Front Rear Suspension: Front Rear Front Suspension Travel Rear Wheel Travel Front Fork Oil: Type Capacity (Per One Unit): Cylinder Unit Outer Tube BRAKES Type: Front Rear Single disc Single disc 180 mL (6.09 US oz.) 369 mL (12.5 US oz.) SHOWA
  • 2010 Kawasaki KX250F | Owners Manual - Page 12
    GENERAL INFORMATION 11 GENERAL INFORMATION Location of Parts j 1. Clutch Lever 2. Hot Starter Lever 3. Engine Stop Button 4. Fuel Tank Cap 5. Front Brake Fluid Reservoir 6. Front Brake Lever 7. Throttle Grip
  • 2010 Kawasaki KX250F | Owners Manual - Page 13
    12 GENERAL INFORMATION j 8. Front Fork 9. Radiator 10. Fuel Tap 11. Fuel Tank 12. Carburetor 13. Seat 14. Air Cleaner Element 15. Brake Disc 16. Brake Caliper 17. Shift Pedal 18. Rear Shock Absorber 19. Swingarm 20. Drive Chain 21. Chain Guide
  • 2010 Kawasaki KX250F | Owners Manual - Page 14
    GENERAL INFORMATION 13 j 22. Muffler 23. Rear Brake Fluid Reservoir 24. Rear Shock Absorber Gas Reservoir 25. Kick Pedal 26. Uni-Trak® Tie-Rod and Rocker Arm 27. Oil Level Gauge 28. Rear Brake Pedal 29. Exhaust Pipe
  • 2010 Kawasaki KX250F | Owners Manual - Page 15
    B. Rear Axle WARNING Do not start the engine or attempt to ride the motorcycle when the side stand is installed. A. Fuel Tank Cap B. Breather Hose żSupport the motorcycle with a suitable stand to perform maintenance or adjustment procedures. NOTE
  • 2010 Kawasaki KX250F | Owners Manual - Page 16
    with a minimum Antiknock Index of 90. The Antiknock Index is posted on service station pumps in the U.S.A.. The octane rating of a gasoline is a measure standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or
  • 2010 Kawasaki KX250F | Owners Manual - Page 17
    " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is drain all fuel from the fuel system. See the Storage section in this manual. żOther oxygenates approved for use in unleaded NOTE gasoline include TAME (up
  • 2010 Kawasaki KX250F | Owners Manual - Page 18
    GENERAL INFORMATION 17 j Kick Pedal This motorcycle is equipped with a primary kick starting system. When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear. Starting the Engine the transmission into neutral. • Shift • Turn the fuel tap lever to the ON
  • 2010 Kawasaki KX250F | Owners Manual - Page 19
    18 GENERAL INFORMATION j NOTICE This motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in
  • 2010 Kawasaki KX250F | Owners Manual - Page 20
    GENERAL INFORMATION 19 starter lever or choke knob is used as following • Hot table. Engine Condition Already Warm Restarting after falling Cold Hot Starter Lever Pull in (ON) Pull in (ON) No use (OFF) Choke Knob Push back (OFF) Push back (OFF) Use (ON) j A. Hot Starter Lever the engine over,
  • 2010 Kawasaki KX250F | Owners Manual - Page 21
    20 GENERAL INFORMATION j 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
  • 2010 Kawasaki KX250F | Owners Manual - Page 22
    GENERAL INFORMATION 21 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down
  • 2010 Kawasaki KX250F | Owners Manual - Page 23
    , the motorcycle is ready for regular operation. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. NOTICE When any following parts have been replaced, the same break-in procedure as the new motorcycle must be carried out for
  • 2010 Kawasaki KX250F | Owners Manual - Page 24
    GENERAL INFORMATION 23 j 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
  • 2010 Kawasaki KX250F | Owners Manual - Page 25
    24 GENERAL INFORMATION j Muffler ...No damage 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
  • 2010 Kawasaki KX250F | Owners Manual - Page 26
    GENERAL INFORMATION 25 j After-Race Checks After racing, first clean the motorcycle (see P.129), then inspect the entire motorcycle with special attention to the air cleaner, brakes, etc. Carry out the general lubrication (see P.131) and make necessary adjustments.
  • 2010 Kawasaki KX250F | Owners Manual - Page 27
    26 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT j Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. 1. Periodic
  • 2010 Kawasaki KX250F | Owners Manual - Page 28
    MAINTENANCE AND ADJUSTMENT 27 FREQUENCY After each race (or 2.5 hour) Every 3 races (or 7.5 hour) Every 6 races (or 15 hour) Every 12 races (or 30 hour) As See required Page 78 36 - 35 OPERATION Coolant level - inspect Breather hose - inspect j Engine sprocket - inspect † Water hoses and
  • 2010 Kawasaki KX250F | Owners Manual - Page 29
    28 MAINTENANCE AND ADJUSTMENT 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each race (or 2.5 hour) OPERATION Brake - adjust † Brake pad wear - inspect † Brake fluid level - inspect † Spoke tightness and rim runout inspect † Drive chain - inspect and adjust Drive chain - lubricate
  • 2010 Kawasaki KX250F | Owners Manual - Page 30
    MAINTENANCE AND ADJUSTMENT 29 FREQUENCY After each race (or 2.5 hour) Every 3 races (or 7.5 hour) Every 6 races (or 15 hour) Every 12 As See races (or required Page 30 hour) - - - 120 - OPERATION j Swingarm and UNI-TRAK linkage K pivots - inspect † K Swingarm and UNI-TRAK linkage pivots -
  • 2010 Kawasaki KX250F | Owners Manual - Page 31
    2 years Every 2 years Every 2 years Every 4 years • - 69 40 - - - - 91 - - K Brake hoses - replace • Every 4 years • †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
  • 2010 Kawasaki KX250F | Owners Manual - Page 32
    seizure, accident, and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the owner's manual. Because of the semi-dry sump lubrication system, the engine oil level indicated on the oil level gauge will fluctuate depending on the motorcycle
  • 2010 Kawasaki KX250F | Owners Manual - Page 33
    32 MAINTENANCE AND ADJUSTMENT j żIf no oil appears in the oil level gauge, tip the mo- NOTE Oil and/or Oil Filter Change The engine oil and/or oil filter should be changed periodically to ensure long engine life. Warm up the engine thoroughly so that the oil will pick up any sediment and drain
  • 2010 Kawasaki KX250F | Owners Manual - Page 34
    MAINTENANCE AND ADJUSTMENT 33 the oil filter is replaced, remove the oil filter • When cap bolts and take off the cap with O-ring. the oil filter element with a new one. • Replace Apply grease to the grommet. • Install the oil filter • ward the engine. element with the grommet to- j NOTICE Inside-
  • 2010 Kawasaki KX250F | Owners Manual - Page 35
    34 MAINTENANCE AND ADJUSTMENT Tightening Torque Oil Filter Cap Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) the oil has completely drained out, install the • After drain bolt with its new gasket. Proper torque for it is shown in the table. Tightening Torque Engine Oil Drain Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb
  • 2010 Kawasaki KX250F | Owners Manual - Page 36
    MAINTENANCE AND ADJUSTMENT 35 • Tighten the oil filler plug. Tightening Torque Oil Filler Plug: 5.0 N·m (0.51 kgf·m, 44 in·lb) Cooling System Water Hoses Check the water hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. j • •
  • 2010 Kawasaki KX250F | Owners Manual - Page 37
    36 MAINTENANCE AND ADJUSTMENT WARNING j The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns. the motorcycle perpendicular to the • Situate ground
  • 2010 Kawasaki KX250F | Owners Manual - Page 38
    MAINTENANCE AND ADJUSTMENT 37 the coolant level in the radiator. The • Check coolant should come up to the bottom of the radiator filler neck. Water and Antifreeze Mixing Ratio 1:1 (water:antifreeze) Recommended Antifreeze Permanent type of antifreeze (ethylene glycol plus corrosion and rust
  • 2010 Kawasaki KX250F | Owners Manual - Page 39
    38 MAINTENANCE AND ADJUSTMENT inspect the old coolant. • Visually If whitish cotton-like wafts are observed, aluminum • parts in the cooling system are corroded and the the coolant is brown, iron or steel parts are rust• If ing and the system must be flushed. the cooling system for damage, loose con
  • 2010 Kawasaki KX250F | Owners Manual - Page 40
    MAINTENANCE AND ADJUSTMENT 39 NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacture. Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the
  • 2010 Kawasaki KX250F | Owners Manual - Page 41
    40 MAINTENANCE AND ADJUSTMENT If the plug is oily or has carbon built up on it, clean it (preferably with a sandblaster) and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other suitable tool. If the spark plug electrodes are
  • 2010 Kawasaki KX250F | Owners Manual - Page 42
    MAINTENANCE AND ADJUSTMENT 41 the fuel tap lever to the OFF position. • Turn Slide • out the clamp and pull off the fuel hose. the fuel tank mounting bolt and band. • Remove Remove the fuel tank. • NOTICE Take care not to give excessive forces to the fuel hose to prevent damage. Do not use the
  • 2010 Kawasaki KX250F | Owners Manual - Page 43
    42 MAINTENANCE AND ADJUSTMENT the stick coil connector. • Disconnect Pull out the stick coil off the plug. • the stick coil. • Install Turn the • bolt. connector to the front cylinder head cover up the stick coil lightly to make sure of the • Pull installation of the stick coil. j NOTICE Do not
  • 2010 Kawasaki KX250F | Owners Manual - Page 44
    MAINTENANCE AND ADJUSTMENT 43 Air Cleaner A clogged air cleaner restricts the air intake, increases 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 carburetor, and the duct clamps and
  • 2010 Kawasaki KX250F | Owners Manual - Page 45
    44 MAINTENANCE AND ADJUSTMENT the both side covers slightly outward and • Open slide the seat backward. the wing bolt, and take out the air cleaner • Remove element. j A. Side Covers B. Seat A. Air Cleaner Element B. Wing Bolt inside of the intake tract and carburetor for • Check dirt. If dirty,
  • 2010 Kawasaki KX250F | Owners Manual - Page 46
    MAINTENANCE AND ADJUSTMENT 45 the element. If it is dirty, clean it. Also • Inspect check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into the carburetor. j WARNING A clogged air cleaner may allow dirt and dust to
  • 2010 Kawasaki KX250F | Owners Manual - Page 47
    46 MAINTENANCE AND ADJUSTMENT WARNING j Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point
  • 2010 Kawasaki KX250F | Owners Manual - Page 48
    MAINTENANCE AND ADJUSTMENT 47 installation, check the element for damage • Before such as tears, hardening, or shrinkage. If damgrease to all mating surfaces and to the • Apply screw hole in the air cleaner housing and intake aged, replace the element. the air cleaner element so that its tab faces •
  • 2010 Kawasaki KX250F | Owners Manual - Page 49
    48 MAINTENANCE AND ADJUSTMENT Throttle Cable j 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. Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of
  • 2010 Kawasaki KX250F | Owners Manual - Page 50
    MAINTENANCE AND ADJUSTMENT 49 Carburetor Idle Speed Adjustment Idle speed adjustment is carried out using the pilot screw and the idle adjusting screw. First turn the pilot screw with the pilot screw adjuster D (special tool: 57001-1588) in until it is lightly seated, then back it out 2 1/8 turns.
  • 2010 Kawasaki KX250F | Owners Manual - Page 51
    50 MAINTENANCE AND ADJUSTMENT WARNING j Operation with damaged cables could result in an unsafe riding condition. Replace damaged control cables before operation. Cleaning the Carburetor NOTICE This motorcycle's radiator does not incorporate cooling fan. Prolonged idling of the engine with no
  • 2010 Kawasaki KX250F | Owners Manual - Page 52
    MAINTENANCE AND ADJUSTMENT 51 the rear frame mounting bolts on the left • Remove and right sides. the rear frame backward with the air cleaner • Pull housing. • Disconnect the throttle sensor connector. j A. Throttle Sensor Connector A. Rear Frame Mounting Bolts B. Air Cleaner Housing
  • 2010 Kawasaki KX250F | Owners Manual - Page 53
    52 MAINTENANCE AND ADJUSTMENT the carburetor clamp screw. • Loosen Free the hoses. • Pull the carburetor from the holder. • • Remove the cap bolt and hot starter plunger. j A. Hot Starter Plunger Cap Bolt B. Hot Starter Plunger A. Carburetor Clamp Screw
  • 2010 Kawasaki KX250F | Owners Manual - Page 54
    MAINTENANCE AND ADJUSTMENT 53 the fuel from the float bowl by removing the • Drain drain screw. After draining, install the drain screw securely. the bolt, and take off the throttle pulley • Remove cover. j A. Float Bowl B. Drain Screw A. Throttle Pulley Cover Bolt B. Throttle Pulley Cover
  • 2010 Kawasaki KX250F | Owners Manual - Page 55
    54 MAINTENANCE AND ADJUSTMENT the throttle cable bolts, and free the tips of • Loosen throttle cable lower end. the lower ends of the throttle cables and • Lubricate reinstall them in reverse order of removal. Tightening Torque Throttle Cable Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) Throttle Pulley
  • 2010 Kawasaki KX250F | Owners Manual - Page 56
    MAINTENANCE AND ADJUSTMENT 55 the carburetor to the carburetor • Install Align the projection with the groove. • Check the holder is installed securely. holder. the throttle sensor connector. • Connect Install the rear frame with the air cleaner housing • to the carburetor. Align the groove with the
  • 2010 Kawasaki KX250F | Owners Manual - Page 57
    56 MAINTENANCE AND ADJUSTMENT Tightening Torque Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) the carburetor air vent and overflow hoses • Run properly. the removed parts. • Install Open and close the throttle a few times to make • sure the grip operates correctly. the throttle cable play
  • 2010 Kawasaki KX250F | Owners Manual - Page 58
    MAINTENANCE AND ADJUSTMENT 57 the number plate (see Steering section). • Remove Turn the in all the way. • Slide the adjuster dust cover • Loosen the locknut inback. the middle of the clutch ca• ble, and turn the adjusting nut so that the clutch lever free play is 8 ∼ 13 mm (0.3 ∼ 0.5 in.). •
  • 2010 Kawasaki KX250F | Owners Manual - Page 59
    58 MAINTENANCE AND ADJUSTMENT Friction and Steel Plates Removal j • • Drain the engine oil (see Engine Oil section). Remove the brake pedal bolt and the rear brake pedal return spring. • Remove the clutch cover bolts. A. Bolts B. Clutch Cover A. Brake Pedal Bolt B. Brake Pedal C. Return Spring
  • 2010 Kawasaki KX250F | Owners Manual - Page 60
    • If friction plates and steel plates as a set. the thickness of the friction and steel • Measure plates with vernier calipers. they have worn past the service limit, replace • If them with new ones. Friction Plate Thickness Measurement Standard 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in
  • 2010 Kawasaki KX250F | Owners Manual - Page 61
    with a thickness gauge (i.e., the gap between the surface plate and each friction plate or steel plate). If any plate is warped over the service limit, replace it with a new one. A. Surface Plate B. Friction or Steel Plate C. Thickness Gauge • Friction and Steel Plate Installation all parts in
  • 2010 Kawasaki KX250F | Owners Manual - Page 62
    MAINTENANCE AND ADJUSTMENT 61 molybdenum disulfide grease to the steel • Apply ball and the contact area of the push rod holder. • Install the steel ball and the push rod holder. j A. Friction and Steel Plates NOTICE If dry steel plates and friction plates are installed, apply engine oil to the
  • 2010 Kawasaki KX250F | Owners Manual - Page 63
    62 MAINTENANCE AND ADJUSTMENT j A. B. C. D. Release Shaft Lever Push forward. Position Distance Cable Bracket A. B. C. D. Adjusting Washer Push Rod Holder Needle Bearing Circlip the lever position is not within the standard, se• If lect the correct thickness of adjusting washer ac- • cording
  • 2010 Kawasaki KX250F | Owners Manual - Page 64
    MAINTENANCE AND ADJUSTMENT 63 Release Shaft Lever Position and Adjusting Washer Selection Position JudgWashers QuanDistance ment Thickness tity 49.2 ∼ 56.5 mm Standard (1.94 ∼ 2.22 in.) More than 56.5 mm (2.22 in.) Less than 49.2 mm (1.94 in.) Too big Too small 1.5 mm (0.06 in.) 1.0 mm (0.04 in.)
  • 2010 Kawasaki KX250F | Owners Manual - Page 65
    64 MAINTENANCE AND ADJUSTMENT Valve Clearance j Valve and valve seat wear decreases valve clearance, upsetting valve timing. the cylinder head cover bolts and cylinder • Remove head cover. NOTICE If valve clearance is left unadjusted, wear will eventually cause the valves to remain partly open,
  • 2010 Kawasaki KX250F | Owners Manual - Page 66
    MAINTENANCE AND ADJUSTMENT 65 the head cover gasket and spark plug • Remove hole gasket. • Remove the two caps from the magneto cover. j A. Head Cover Gasket B. Spark Plug Hole Gasket A. Timing Inspection Cap B. Flywheel Nut Cap
  • 2010 Kawasaki KX250F | Owners Manual - Page 67
    66 MAINTENANCE AND ADJUSTMENT the piston to the Top Dead Center (TDC) of • Bring its compression stroke to inspect the valve clearthis point, the timing marks on the camshaft • At sprockets must be almost aligned with the cylinder head upper surface as shown in the figure. j ance (the position at
  • 2010 Kawasaki KX250F | Owners Manual - Page 68
    specified • If range, adjust by an authorized Kawasaki dealer or j żRecord the measured valves clearance. NOTE • a competent mechanic following the instructions in the Service Manual. Apply silicone sealant to the cylinder head as shown in the figure. A. Thickness Gauge A. Silicone Sealant
  • 2010 Kawasaki KX250F | Owners Manual - Page 69
    on the cylinder head. • Replace the spark plug hole gasket with a new • one, and install it. sure that the upper chain guide is bottomed • Make to the cylinder head cover. j A. Upper Chain Guide B. Cylinder Head Cover A. Head Cover Gasket B. Spark Plug Hole Gasket NOTICE Unless the upper chain
  • 2010 Kawasaki KX250F | Owners Manual - Page 70
    MAINTENANCE AND ADJUSTMENT 69 Tightening Torque Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Exhaust System The exhaust system, in particular the muffler body, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon
  • 2010 Kawasaki KX250F | Owners Manual - Page 71
    70 MAINTENANCE AND ADJUSTMENT the muffler body cover bolts. • Remove Remove the muffler mounting bolt. • the muffler body cover with the plastic • Remove mallet. j A. Muffler Body Cover Bolts B. Muffler Mounting Bolt A. Plastic Mallet B. Muffler Body Cover
  • 2010 Kawasaki KX250F | Owners Manual - Page 72
    MAINTENANCE AND ADJUSTMENT 71 the muffler baffle with a new one. • Replace Remove the silicone sealant attaching on the muf• fler body cover and muffler body. the shape of the muffler baffle and install • Arrange the muffler body cover to the muffler body. that the exhaust port of the muffler body •
  • 2010 Kawasaki KX250F | Owners Manual - Page 73
    72 MAINTENANCE AND ADJUSTMENT j A. B. C. D. Muffler Body Cover Muffler Body Muffler Body Cover Bolts Silicone Sealant A. Muffler Clamp Bolt B. Muffler Mounting Bolt C. Muffler Body żIf NOTE the threaded holes of the muffler body cover and muffler body do not align, remove the muffler clamp
  • 2010 Kawasaki KX250F | Owners Manual - Page 74
    MAINTENANCE AND ADJUSTMENT 73 Drive Chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated before riding. If the chain becomes badly worn or maladjusted - either too loose or too tight - it could jump off the sprockets or break. j WARNING A chain
  • 2010 Kawasaki KX250F | Owners Manual - Page 75
    74 MAINTENANCE AND ADJUSTMENT the same swingarm mark that the notch of the right chain adjuster aligns with. j Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) żWheel alignment can also be checked using the straightedge or string method. NOTE WARNING Misalignment of the wheel will result in
  • 2010 Kawasaki KX250F | Owners Manual - Page 76
    MAINTENANCE AND ADJUSTMENT 75 j A. Cotter Pin A. Turning Clockwise żWhen inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise up to the next alignment. żIt should be within 30°. żLoosen once and tighten again when the slot
  • 2010 Kawasaki KX250F | Owners Manual - Page 77
    pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since overworn sprockets will cause a new Chain 20-Link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 Standard in.) Service Limit 323 mm (12.7 in.) drive system was designed for use with a DAIDO DID
  • 2010 Kawasaki KX250F | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 Chain Guide Wear Inspection inspect the drive chain guide and replace • Visually it if excessively worn or damaged. j A. Master Link Clip B. Direction of Chain Rotation A. Chain Guide
  • 2010 Kawasaki KX250F | Owners Manual - Page 79
    78 MAINTENANCE AND ADJUSTMENT Chain Slipper Wear Inspection j • Sprocket Wear Inspection Visually inspect the upper and lower of the chain slipper on the swingarm and replace them if worn or damaged. inspect the sprocket teeth and replace the • Visually sprocket if its teeth are worn or damaged
  • 2010 Kawasaki KX250F | Owners Manual - Page 80
    MAINTENANCE AND ADJUSTMENT 79 Chain Lubrication Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry. A heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. Apply oil
  • 2010 Kawasaki KX250F | Owners Manual - Page 81
    of the clamp after the bolts torqued. Tightening Torque Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) A. B. C. D. Handlebar Clamps Clamp Bolts Gap Supporting Bar not disassemble the supporting bar on the han• Do dlebar. the front brake for the proper brake effect, • Check or no brake drag.
  • 2010 Kawasaki KX250F | Owners Manual - Page 82
    MAINTENANCE AND ADJUSTMENT 81 Brakes Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. There are no parts on the brakes that require adjustment except brake lever position. the braking power and check that there is no • Test brake drag.
  • 2010 Kawasaki KX250F | Owners Manual - Page 83
    82 MAINTENANCE AND ADJUSTMENT NOTICE j Do not spill brake fluid onto any painted surface. 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 system fittings. Check for brake hose damage. Brake Fluid Level
  • 2010 Kawasaki KX250F | Owners Manual - Page 84
    MAINTENANCE AND ADJUSTMENT 83 WARNING Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled
  • 2010 Kawasaki KX250F | Owners Manual - Page 85
    84 MAINTENANCE AND ADJUSTMENT Brake Pad Wear Inspection Inspect the brake pads for wear in accordance with the Periodic Maintenance Chart. If the thickness of any pad in any (front or rear) brake caliper is less than 1 mm (0.04 in.), have both pads in the caliper replaced as a set. Pad replacement
  • 2010 Kawasaki KX250F | Owners Manual - Page 86
    MAINTENANCE AND ADJUSTMENT 85 Steering Adjustment the front wheel off the ground using a jack • Raise (special tool: 57001-1238) and attachment (spe- • • • cial tool: 57001-1252 or 1608). Unlock the clamp of the number plate. Remove the bolt. Clear the holes and remove the number plate. j A.
  • 2010 Kawasaki KX250F | Owners Manual - Page 87
    86 MAINTENANCE AND ADJUSTMENT the handlebar (see Handlebar section). • Remove Loosen the left and right front fork clamp bolts (up• per). the steering stem head nut, and raise the • Remove steering stem head. the steering stem locknut with a stem nut • Turn wrench (special tool: 57001-1100) to
  • 2010 Kawasaki KX250F | Owners Manual - Page 88
    Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Front Suspension Front Fork Inspection the brake lever, pump the front fork back • Holding and forth manually to check for smooth operation. inspect the front fork for oil leakage, scor• Visually ing or scratches on the outer surface of the inner
  • 2010 Kawasaki KX250F | Owners Manual - Page 89
    88 MAINTENANCE AND ADJUSTMENT NOTICE j If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straitening, can weaken the inner tube. Front Fork Adjustment Any of the following front fork adjustments should be made to tune the front suspension to the
  • 2010 Kawasaki KX250F | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 Air Pressure Adjustment The standard air pressure in the front fork legs is atmospheric (0 kPa, 0 kgf/cm², 0 psi). Air pressure in the fork legs increase with normal use, so the fork action stiffens during operation. Release air pressure from the fork legs prior to
  • 2010 Kawasaki KX250F | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings a flat-head screwdriver. Adjust the compression damping to suit your preference under certain conditions. j NOTICE Do not force the compression damping adjuster beyond the fully seated position, or the adjusting mechanism may be
  • 2010 Kawasaki KX250F | Owners Manual - Page 92
    MAINTENANCE AND ADJUSTMENT 91 Compression Damping Adjuster Settings Standard Compression Setting 10 clicks* Damping Adjuster j *: Counterclockwise from the fully seated position Front Fork Oil Change • Thoroughly clean the fork before disassembly. NOTICE Be careful not to scratch the inner tube
  • 2010 Kawasaki KX250F | Owners Manual - Page 93
    (upper). • Loosen Loosen the front fork cylinder unit with the top plug • wrench (special tool: 57001-1645). the motorcycle using a jack (special tool: • Support 57001-1238) and attachment (special tool: 57001 the front axle nut, and then loosen the • Unscrew left front axle clamp bolts. the brake
  • 2010 Kawasaki KX250F | Owners Manual - Page 94
    MAINTENANCE AND ADJUSTMENT 93 the right front axle clamp bolts. • Loosen Place a stand under the engine to raise • the front suitable wheel off the ground. the front axle, and pull out the front wheel. • Remove Take off the collar and cap from each side of the front hub. the front fork clamp bolts (
  • 2010 Kawasaki KX250F | Owners Manual - Page 95
    94 MAINTENANCE AND ADJUSTMENT the length between the axle holder and • Measure outer tube and record it before disassembling the the top plug wrench (special tool: 57001 • Using -1645), remove the fork cylinder unit from the outer tube and slowly slide down the outer tube. 317 ∼ 321 mm (12.48 ∼ 12.
  • 2010 Kawasaki KX250F | Owners Manual - Page 96
    MAINTENANCE AND ADJUSTMENT 95 a drain pan under the front fork and drain • Place fork oil. żPump the outer tube several times to discharge the fork oil. NOTE j A. Fork Cylinder Unit B. Outer Tube C. Top Plug Wrench (Special Tool: 57001-1645) • Hold the axle holder with a vise. WARNING A. Fork
  • 2010 Kawasaki KX250F | Owners Manual - Page 97
    96 MAINTENANCE AND ADJUSTMENT • Loosen the adjuster assembly completely. j WARNING The fork spring applies pressure to the adjuster assembly and can eject the special tool with substantial force if the tool is not properly and securely placed. Be sure the tool is fully in place as shown in the
  • 2010 Kawasaki KX250F | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 żDo not remove the locknut from the piston rod. The piston rod may slide into the inner tube. NOTE • Remove the push rod. j A. Push Rod A. Locknut B. Wrench C. Adjuster Assembly the outer tube compressed by hand, remove • With the top plug wrench (special tool:
  • 2010 Kawasaki KX250F | Owners Manual - Page 99
    98 MAINTENANCE AND ADJUSTMENT the fork leg from the vise. • Remove Loosen the fork cylinder unit with the top plug • wrench (special tool: 57001-1645). the fork cylinder unit and fork spring from • Remove the outer tube. j A. Fork Cylinder Unit B. Outer Tube C. Top Plug Wrench (Special Tool: 57001
  • 2010 Kawasaki KX250F | Owners Manual - Page 100
    the piston rod until it stops so that the base valve assembly can be removed easily. NOTICE Disassembling the base valve assembly can lead to trouble. Do not disassemble the base valve assembly. the fork oil from the fork cylinder unit by • Drain pumping the piston rod several times. the front
  • 2010 Kawasaki KX250F | Owners Manual - Page 101
    100 MAINTENANCE AND ADJUSTMENT the piston rod fully stretched, pour 180 mL • With (6.09 US oz.) of fork oil. j the threads of fork cylinder unit and base • Clean valve assembly. A. Fork Oil B. Fork Cylinder Unit Recommended Fork Oil SHOWA SS19 or equivalent SAE 5W A. Threads
  • 2010 Kawasaki KX250F | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 the piston rod slowly several times to expel • Pump air. j A. 42 ∼ 49 mm (1.65 ∼ 1.93 in.) B. Oil Level A. Pump B. Piston Rod the piston rod fully stretched, check the oil • With level in the fork cylinder unit. Oil Level 42 ∼ 49 mm (1.65 ∼ 1.93 in.) the O-rings on
  • 2010 Kawasaki KX250F | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT j A. O-rings B. Bushings the piston rod held immovable fully stretched, • With gently install the base valve assembly to the fork cylinder unit. A. Top Plug Wrench (Special Tool: 57001-1645) B. Base Valve Assembly C. Fork Cylinder Unit żIf there is difficulty in
  • 2010 Kawasaki KX250F | Owners Manual - Page 104
    with the compressed air blow to the oil NOTICE Be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil flies out from the oil hole of the cylinder unit. • • hole. Wipe the oil off completely from the fork cylinder unit. If
  • 2010 Kawasaki KX250F | Owners Manual - Page 105
    104 MAINTENANCE AND ADJUSTMENT the piston rod operation is not smooth, check the • If piston rod for bend or damage. the fork cylinder unit on level ground while • Hold piston rod is full stroked by your hand. the piston rod then check the piston rod • Release extend to maximum. the piston rod does
  • 2010 Kawasaki KX250F | Owners Manual - Page 106
    MAINTENANCE AND ADJUSTMENT 105 the locknut fully and measure 10 ∼ 12 mm • Tighten (0.39 ∼ 0.47 in.) as shown in the figure. wipe off the fork oil from the spring and • Completely fork cylinder unit. • Insert above-mentioned parts into the fork. j A. 10 ∼ 12 mm (0.39 ∼ 0.47 in.) B. Locknut A. Fork
  • 2010 Kawasaki KX250F | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT WARNING j The fork spring applies pressure to the adjuster assembly and can eject the special tool with substantial force if the tool is not properly and securely placed. Be sure the tool is fully in place as shown in the photo, and keep fingers away to avoid getting
  • 2010 Kawasaki KX250F | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 • Insert the push rod into the piston rod. żCheck the push rod installation with its click by turning the push rod right and left. NOTE j A. Adjuster Assembly B. Locknut C. More Than 1 mm (0.04 in.) A. Push Rod B. Turn the rod right and left. the locknut
  • 2010 Kawasaki KX250F | Owners Manual - Page 109
    108 MAINTENANCE AND ADJUSTMENT j A. Locknut B. Wrench C. Adjuster Assembly A. Axle Holder Part B. Adjuster Assembly • • With the outer tube compressed by hands, remove the top plug wrench (special tool: 57001-1645). Apply a non-permanent locking agent and tighten the adjuster assembly to the
  • 2010 Kawasaki KX250F | Owners Manual - Page 110
    MAINTENANCE AND ADJUSTMENT 109 Using the top plug wrench (special tool: 57001 • -1645), remove the fork cylinder unit from the outer tube and slowly slide down the outer tube. j A. Outer Tube B. Fork Oil A. Top Plug Wrench (Special Tool: 57001-1645) B. Fork Cylinder Unit C. Outer Tube NOTICE Be
  • 2010 Kawasaki KX250F | Owners Manual - Page 111
    110 MAINTENANCE AND ADJUSTMENT changing the fork spring, the oil capacity is • When as shown in the table. j SOFT (K = 4.2 N·mm) Adjustable Range Standard Oil 366 mL (12.4 US oz.) Capacity 304 ∼ 402 mL (10.3 ∼ 13.6 US oz.) HARD (K = 4.6 N·mm) Adjustable Range Standard Oil 372 mL (12.6 US oz.)
  • 2010 Kawasaki KX250F | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 żThis torque value (31 N·m (3.1 kgf·m, 23 ft·lb)) is applicable when you use a torque wrench whose length gives leverage of approximately 310 mm (12.2 in.) between the grip point to the center of the coupling square. j a non-permanent locking agent to the front •
  • 2010 Kawasaki KX250F | Owners Manual - Page 113
    15 ft·lb) A. Collars B. Caps C. Axle D. Right Front Axle Clamp Bolts E. Axle Nut F. Left Front Axle Clamp Bolts G. Oil Seals the jack and stand supporting the motor• Remove cycle. tightening the clamp bolts on the right fork • Before leg, loosen the right front axle clamp bolts, and pump the forks
  • 2010 Kawasaki KX250F | Owners Manual - Page 114
    this process to stop the motorcycle from rolling forward. Put a block in front of the wheel to stop it from moving. NOTE WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an
  • 2010 Kawasaki KX250F | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT Rear Suspension (UNI-TRAK®) j This motorcycle's rear suspension system is called "UNI-TRAK®" and consists of a rear shock absorber unit, a swingarm, two lever rods and a lever. The operating characteristics of the UNI-TRAK® suspension are similar to those of the front
  • 2010 Kawasaki KX250F | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 Rebound Damping Adjustment To adjust the rear shock absorber rebound damping, turn the rebound damping adjuster at the bottom of the rear shock absorber with a flat-head screwdriver. Rebound Damping Adjuster Settings j A. Rebound Damping Adjuster A. Seated
  • 2010 Kawasaki KX250F | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT j żAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force. Always make any damping adjustments in small steps and test their effects before using them in competition. NOTE Compression Reservoir)
  • 2010 Kawasaki KX250F | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 High Speed Compression Damping Adjuster Settings Low Speed Compression Damping Adjuster Settings j A. Seated Position (Adjuster Turned Fully Clockwise) B. Softer (Counterclockwise) C. Harder (Clockwise) D. Standard Setting A. Seated Position (Adjuster Turned Fully
  • 2010 Kawasaki KX250F | Owners Manual - Page 119
    118 MAINTENANCE AND ADJUSTMENT NOTICE j Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. the hook wrenches (special tools: 57001 • Using -1101, 1539), loosen the locknut on the rear shock absorber. żAdjustment of the
  • 2010 Kawasaki KX250F | Owners Manual - Page 120
    MAINTENANCE AND ADJUSTMENT 119 the hook wrench (special tool: 57001-1101), • Using turn the spring preload adjusting nut as required. Turning the adjusting nut down increases the spring preload. Rear Shock Absorber Spring K = 47 N·mm (K = 4.8 kgf·mm) K = 49 N·mm (K = 5.0 kgf·mm) K = 51 N·mm* (K =
  • 2010 Kawasaki KX250F | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT • Tighten the locknut securely. j Tightening Torque Rear Shock Absorber Spring Locknut: 45 N·m (4.6 kgf·m, 33 ft·lb) Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track conditions and rider
  • 2010 Kawasaki KX250F | Owners Manual - Page 122
    MAINTENANCE AND ADJUSTMENT 121 Spokes and Rims The spokes on both wheels must all be securely and evenly tightened and not be allowed to loosen. Unevenly tightened or loose spokes will cause the rim to warp, the nipples and spokes to fatigue more quickly, and the spokes to break. Bead Protector
  • 2010 Kawasaki KX250F | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT up the dial gauge on the inner circumference • Set of the rim and rotate the wheel to measure its ra- j • dial runout. The difference between the highest and lowest readings is the amount of runout. A certain amount of rim warpage (runout) can be corrected by
  • 2010 Kawasaki KX250F | Owners Manual - Page 124
    MAINTENANCE AND ADJUSTMENT 123 Hoses Inspection Check the brake and fuel hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Inspect the brake hose and fittings for deterioration, cracks and signs of leakage by bending or twisting
  • 2010 Kawasaki KX250F | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts j 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. 2. 3. 4. 5. 6. 7. Front
  • 2010 Kawasaki KX250F | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 j 19. Muffler Mounting Bolts 20. Muffler Clamp Bolt 21. Upper Engine Mounting/Bracket Bolts 22. Steering Stem Head Nut 23. Front Master Cylinder Clamp Bolts 24. Rear Master Cylinder Mounting Bolts 25. Rear Brake Disc Mounting Bolts 26. Rear Axle Nut 27. Rocker Arm
  • 2010 Kawasaki KX250F | Owners Manual - Page 127
    126 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. An overtightened nut or bolt
  • 2010 Kawasaki KX250F | Owners Manual - Page 128
    MAINTENANCE AND ADJUSTMENT 127 Fastener Carburetor Holder Clamp Screw Muffler Clamp Bolt Muffler Mounting Bolts Lower Engine Mounting Nut Middle Engine Bracket Nuts Middle Engine Mounting Nut Upper Engine Bracket Bolts Upper Engine Mounting Bolts Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut
  • 2010 Kawasaki KX250F | Owners Manual - Page 129
    128 MAINTENANCE AND ADJUSTMENT Fastener N·m 23 9.8 20 20 34 39 59 98 59 25 98 34 kgf·m 2.3 1.0 2.0 2.0 3.5 4.0 6.0 10.0 6.0 2.5 10.0 3.5 ft·lb 17 87 in·lb 15 15 25 29 44 72 44 18 72 25 2T 2T, AL 2T AL AL, L Remarks L j Rear Brake Disc Mounting Bolts Rear Master Cylinder Mounting Bolts Front Fork
  • 2010 Kawasaki KX250F | Owners Manual - Page 130
    MAINTENANCE AND ADJUSTMENT 129 Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will help
  • 2010 Kawasaki KX250F | Owners Manual - Page 131
    months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use non-abrasive products and apply them according to the instructions on the container. Leather, Vinyl, and Rubber If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner
  • 2010 Kawasaki KX250F | Owners Manual - Page 132
    MAINTENANCE AND ADJUSTMENT 131 Lubrication Lubricate the areas shown in the illustrations of this section with either motor oil or regular grease, after each race and whenever the vehicle has been operated under wet or rainy conditions, especially after using a high-pressure spray washer. Before
  • 2010 Kawasaki KX250F | Owners Manual - Page 133
    132 MAINTENANCE AND ADJUSTMENT • Shift Pedal j Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch Cable Throttle Cable Hot Starter Cable Cable Lubrication • • •
  • 2010 Kawasaki KX250F | Owners Manual - Page 134
    MAINTENANCE AND ADJUSTMENT 133 • • • Apply grease to the following points: Clutch Inner Cable Upper End Throttle Inner Cable Upper End Hot Starter Inner Cable Upper End Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears
  • 2010 Kawasaki KX250F | Owners Manual - Page 135
    closed by pulling the hot starter lever in.) does not give every possible cause for each problem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties. • • • Starting failure or difficulties seized • Valve Valve lifter • Cylinder
  • 2010 Kawasaki KX250F | Owners Manual - Page 136
    TROUBLESHOOTING GUIDE 135 Compression low: Spark plug loose Cylinder head insufficiently tightened Cylinder bolt loose Cylinder or piston worn No , broken, or sticking Piston ring side clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder gasket damaged Decompression trouble
  • 2010 Kawasaki KX250F | Owners Manual - Page 137
    136 TROUBLESHOOTING GUIDE Other: CDI unit defective Brake dragging Clutch slipping Engine over heating Engine oil level too high Engine oil viscosity too high Ignition timing incorrect Drive chain trouble j contaminated with water or foreign matter • Fuel Fuel tank cap air vent obstructed •
  • 2010 Kawasaki KX250F | Owners Manual - Page 138
    TROUBLESHOOTING GUIDE 137 dragging • Brake Clutch • Engineslipping overheating • Engine oil level too high • • Brake Clutch • Engineslipping oil level too high • Engine oil too high • Drive chainviscosity trouble • Engine overloaded: j • Engine oil level too low • Engine oil quality poor or type
  • 2010 Kawasaki KX250F | Owners Manual - Page 139
    138 TROUBLESHOOTING GUIDE Clutch not disengaging properly: Clutch lever play excessive Clutch Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift lever broken Pawl guide plate broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken Shift
  • 2010 Kawasaki KX250F | Owners Manual - Page 140
    TROUBLESHOOTING GUIDE 139 Other noise: Connecting rod small end clearance excessive Connecting rod big bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, chain guide worn Decompression spring broken Flywheel magneto loose Drive chain noise:
  • 2010 Kawasaki KX250F | Owners Manual - Page 141
    140 TROUBLESHOOTING GUIDE Exhaust smoke Excessively white: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Handlebar shakes or vibrates excessively: Tire worn Swingarm sleeve or needle bearing damaged Rim warped or out of balance
  • 2010 Kawasaki KX250F | Owners Manual - Page 142
    TROUBLESHOOTING GUIDE 141 Shock absorption unsatisfactory (suspension too soft): Front fork oil level insufficient and/or front fork leaking oil Front fork oil viscosity too low Front
  • 2010 Kawasaki KX250F | Owners Manual - Page 143
    of the spark plug, make sure the ignition timing is correct, service the air cleaner element and decarbonize the muffler. If your machine has past and then starts running poorly with the same carburetor settings, the problem is almost certain to be elsewhere; changing the carburetor settings in such
  • 2010 Kawasaki KX250F | Owners Manual - Page 144
    TUNING 143 Symptoms when the mixture is too lean Pinging or rattling Erratic acceleration Same as when running out of fuel High engine temperature With pinging or rattling, make sure that the gasoline is fresh and the octane rating sufficient. You might also try a different brand of high-octane
  • 2010 Kawasaki KX250F | Owners Manual - Page 145
    144 TUNING j If you note a particular symptom of too rich or lean mixture in a specific operating range, use the chart to determine which components need adjusting. Use the following information to decide what changes to make. Main Jet The main jet has its greatest effect in the 1/2-to-full -
  • 2010 Kawasaki KX250F | Owners Manual - Page 146
    TUNING 145 allowed to pass through. There are seven grooves in the top of the jet needle in which a clip fits. This clip positions the jet needle in the throttle valve relative to the needle jet. Moving the clip down has the effect of pulling the needle further out of the jet; the mixture is thereby
  • 2010 Kawasaki KX250F | Owners Manual - Page 147
    146 TUNING the spark plug insulator is whitish, the fuel/air • If mixture is too lean. Increase the main jet size by the spark plug insulator is wet, the fuel/air mix• If ture is too rich. Reduce the main jet size by one one step. • j step. Tune the carburetor so that the engine delivers
  • 2010 Kawasaki KX250F | Owners Manual - Page 148
    TUNING 147 j Correction Factor Applied to the Jet Needle and Pilot Screw 1.06 or above 1.06 ∼ 1.02 1.02 ∼ 0.98 Correction Factor Jet Needle Setting Pilot Screw Opening lower clip one position one turn out 1/2 turn out same same 0.98 ∼ 0.94 0.94 or below raise clip one position 1/2 turn in one
  • 2010 Kawasaki KX250F | Owners Manual - Page 149
    148 TUNING Standard Carburetor Settings Pilot Screw Opening Throttle Valve Diameter Pilot Jet Jet Needle Jet Needle Clip Position Main Jet 2 1/8 1.5 #40 NHJT 4th #185 the jet needle clip position and pilot screw • Change opening according to the appropriate chart on the previous page. EXAMPLE: For a
  • 2010 Kawasaki KX250F | Owners Manual - Page 150
    POSITIONING on the machine. Before changing the suspension settings, test changing your riding posture or position to check whether it is the cause of the problem or not. It is a wise practice to adjust the suspension to suit the rider's strong points. If you are fast in the corners, adjust the
  • 2010 Kawasaki KX250F | Owners Manual - Page 151
    : oil capacity too high • Fork Fork • air pressure high Spring OK, but suspension too hard: oil deteriorated • Fork • Fork air pressure high • Troubleshooting Improper Settings Listed below are some symptoms of improper suspension settings and the most likely means of correcting them. The proper
  • 2010 Kawasaki KX250F | Owners Manual - Page 152
    TUNING 151 Rear shock absorber improper adjustment symptoms Too Hard Suspension too stiff: Compression damping too high Spring too hard or less, or if his riding experience and ability are much above or below the intermediate level, it is likely that a few basic suspension adjustments will be
  • 2010 Kawasaki KX250F | Owners Manual - Page 153
    152 TUNING Suspension Tuning According the Type of Course Lower the front end slightly. (Increase the amount of fork tube protrusion above the steering stem head by 5 mm Many Corners (0.20 in.)). This accelerates steering and enhances turning ability. Raise the front end slightly. (Decrease the
  • 2010 Kawasaki KX250F | Owners Manual - Page 154
    the rider's preferences. • Use a softer spring. żLighter NOTE or less experienced riders may need a softer spring. Front and Rear Suspension Troubleshooting Front End Surges Downhill or During Acceleration Out of Corner The front suspension is too soft. Increase the compression damping. Increase
  • 2010 Kawasaki KX250F | Owners Manual - Page 155
    154 TUNING Front and Rear Ends Bottom Off After a High-speed Jump (harsh bottoming occurs once or twice per lap) The front suspension is too soft. Increase the fork oil capacity. Use a harder spring. • • j żThe rear shock absorber behavior on this machine may mislead some riders. żThe rear shock
  • 2010 Kawasaki KX250F | Owners Manual - Page 156
    TUNING 155 Gearing Selection of the Secondary Reduction Ratio (Rear Sprocket) Rear Sprocket Selection According to Course Conditions Fast Course Small sprocket Many Curves or Hills Sandy or Soft Ground Large sprocket it is difficult to set the machine so it is best • Since suited for all portions
  • 2010 Kawasaki KX250F | Owners Manual - Page 157
    156 TUNING Special Care According to Track Conditions dry, dusty conditions (such a volcanic ash or • In fine powdery dust), special care must be given to • j keeping the air cleaner element clean. When riding on wet, heavy clay, mud adheres to the tires and other parts of the vehicle. The
  • 2010 Kawasaki KX250F | Owners Manual - Page 158
    OPTIONAL PARTS 157 OPTIONAL PARTS Carburetor #172 #175 #178 #180 Main Jet #182 #185 (Standard) #188 #190 #192 #35 #38 Pilot Jet #40 (Standard) #42 #45 Ļ Leaner Jet Needle Ļ Leaner Richer Ĺ Carburetor Richer Ĺ NHJR NHJS NHJT (Standard) NHJU NHJV NHKR NHKS NHKT NHKU NHKV żNHJ is 0.5 clip position
  • 2010 Kawasaki KX250F | Owners Manual - Page 159
    158 OPTIONAL PARTS Engine Sprocket 12T 13T (Standard) Rear Sprocket 46T 47T Aluminum 48T (Standard) 49T 50T 46T 47T Steel 48T 49T 50T Front Rear Front Rear Front and Rear Steel Disc Plate No holes (for wet conditions) No holes (for wet conditions) 21 × 1.60 19 × 1.85 Spoke Nipple Rear Front
  • 2010 Kawasaki KX250F | Owners Manual - Page 160
    engine, cylinder, piston and crankshaft bearings will be damaged. After riding, inspect the crankshaft big end. If the crankshaft big end is worn past the service limit, replace the crankshaft with a new one. Maintenance After Riding in the Rain or on a Muddy Course Apply grease to swingarm and rear
  • 2010 Kawasaki KX250F | Owners Manual - Page 161
    160 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE the drive chain and rear sprocket for wear. • Inspect Clean the cleaner element. • Check the air cylinder crankshaft big end. • Grease the throttle and grip and control cables. • Suggested Spare Parts and rear wheels • Front Shift pedal brake pedal •
  • 2010 Kawasaki KX250F | Owners Manual - Page 162
    STORAGE 161 STORAGE Before Storage When the motorcycle is to be stored for any length of time, it should be prepared for storage as follows. Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, then stop it and drain the engine oil. WARNING Gasoline is
  • 2010 Kawasaki KX250F | Owners Manual - Page 163
    162 STORAGE After Storage the plastic bag from the muffler. • Remove • Make sure the spark plug is tight. żFit the plug cap securely onto the spark plug, and the fuel tank with fuel. • Fill all the points listed in the Daily Pre-Ride • Check Checks section. a lubrication procedure in the
  • 2010 Kawasaki KX250F | Owners Manual - Page 164
    ENVIRONMENTAL PROTECTION 163 ENVIRONMENTAL PROTECTION To protect our environment, properly discard used tires, engine oil, or other vehicle components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for the proper disposal
  • 2010 Kawasaki KX250F | Owners Manual - Page 165
    164 WIRING DIAGRAM WIRING DIAGRAM
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