2015 Kawasaki KX250F Owners Manual

2015 Kawasaki KX250F Manual

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  • 2015 Kawasaki KX250F | Owners Manual - Page 1
  • 2015 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.
  • 2015 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.
  • 2015 Kawasaki KX250F | Owners Manual - Page 4
    shown below, heed their instructions! Always follow safe operating FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. DANGER DANGER indicates a hazardous situation which, if not responsibilities concerning quality, performance, cost of service and/or necessary repairs. NOTICE NOTICE is
  • 2015 Kawasaki KX250F | Owners Manual - Page 5
    conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR
  • 2015 Kawasaki KX250F | Owners Manual - Page 6
    WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • 2015 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 8
    (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
  • 2015 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
  • 2015 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 28.7°
  • 2015 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 Amount (Left Front Fork): Cylinder Unit Outer Tube Amount (Right Front Fork) BRAKES Type: Front Rear Single disc Single disc 330 mL (11.2 US oz.)
  • 2015 Kawasaki KX250F | Owners Manual - Page 12
    GENERAL INFORMATION 11 GENERAL INFORMATION Location of Labels All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your
  • 2015 Kawasaki KX250F | Owners Manual - Page 13
    12 GENERAL INFORMATION j 2. Brake Fluid (Rear) 3. Radiator Cap Danger 4. Rear Shock Absorber Warning
  • 2015 Kawasaki KX250F | Owners Manual - Page 14
    GENERAL INFORMATION 13 j 5. Noise Emission Control Information 6. Important Information 7. Disclaimer of Warranty
  • 2015 Kawasaki KX250F | Owners Manual - Page 15
    14 GENERAL INFORMATION 1) 3) j 2) 4)
  • 2015 Kawasaki KX250F | Owners Manual - Page 16
    GENERAL INFORMATION 15 5) 7) j 6)
  • 2015 Kawasaki KX250F | Owners Manual - Page 17
    16 GENERAL INFORMATION j Location of Parts 1. Clutch Lever 2. Engine Stop Button 3. Launch Control Mode Button 4. Orange Launch Control Mode/FI Warning Indicator Light 5. Fuel Tank Cap 6. Front Brake Fluid Reservoir 7. Front Brake Lever 8. Throttle Grip
  • 2015 Kawasaki KX250F | Owners Manual - Page 18
    GENERAL INFORMATION 17 j 1. Front Fork 2. Radiator 3. Fuel Tank 4. Throttle Body Assy 5. Downstream Injector 6. Upstream Injector 7. Seat 8. Air Cleaner Element 9. Brake Disc 10. Brake Caliper 11. Shift Pedal 12. Rear Shock Absorber 13. Swingarm 14. Drive Chain 15. Chain Guide
  • 2015 Kawasaki KX250F | Owners Manual - Page 19
    18 GENERAL INFORMATION j 1. Muffler 2. Rear Brake Fluid Reservoir 3. Rear Shock Absorber Gas Reservoir 4. Kick Pedal 5. DFI Setting Data Selection Connector 6. Uni-Trak® Tie-Rod and Rocker Arm 7. Oil Level Inspection Window 8. Rear Brake Pedal 9. Exhaust Pipe
  • 2015 Kawasaki KX250F | Owners Manual - Page 20
    GENERAL INFORMATION 19 Side Stand To install the side stand, insert its flat end into the rear axle as shown in the figure. ○Support the motorcycle with a suitable stand to perform maintenance or adjustment procedures. NOTE j A. Side Stand B. Rear Axle WARNING Riding with the side stand can
  • 2015 Kawasaki KX250F | Owners Manual - Page 21
    20 GENERAL INFORMATION j Fuel This Kawasaki KX has a 4-stroke engine that requires a gasoline. The capacity of the fuel tank is 6.1 L (1.6 US gal). To open the fuel tank cap, disconnect the breather hose from the hole in the steering stem, and turn the tank cap counterclockwise. Avoid filling the
  • 2015 Kawasaki KX250F | Owners Manual - Page 22
    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 standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended
  • 2015 Kawasaki KX250F | Owners Manual - Page 23
    " containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is you drain all fuel from the fuel system. See the Storage section in this manual. ○Other oxygenates approved for use in unleaded gasoline include TAME (up to 16
  • 2015 Kawasaki KX250F | Owners Manual - Page 24
    GENERAL INFORMATION 23 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 • Shift the transmission into neutral. WARNING Riding with the side stand can
  • 2015 Kawasaki KX250F | Owners Manual - Page 25
    24 GENERAL INFORMATION When engine is cold Pull out the idle adjusting screw/choke knob. j • When engine is already warm or restarts Kick the engine over, leaving the throttle closed without using the idle adjusting screw/choke knob. • ○If the engine fails starting, open the throttle fully
  • 2015 Kawasaki KX250F | Owners Manual - Page 26
    GENERAL INFORMATION 25 Launch Control Mode The launch control mode can be used to adjust ignition timing to help riders get better starts on slippery terrain. The system's effectiveness is dependent on rider skill, technique and terrain conditions. shifting into 3rd, the system is deactivated •
  • 2015 Kawasaki KX250F | Owners Manual - Page 27
    26 GENERAL INFORMATION j DFI Setting Data Selection Three DFI settings are available to suit various track conditions. They are easily activated by changing the wiring connector on the side of the frame when the engine is stopped. Track Condition Soft Standard Hard Connector Color White Green Black
  • 2015 Kawasaki KX250F | Owners Manual - Page 28
    GENERAL INFORMATION 27 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 29
    28 GENERAL INFORMATION 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 30
    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. j NOTICE When any following parts have been replaced, the same break-in procedure as the new motorcycle must be carried out for
  • 2015 Kawasaki KX250F | Owners Manual - Page 31
    30 GENERAL INFORMATION 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 32
    GENERAL INFORMATION 31 Properly installed Engine Sprocket ...No wear or damage Frame Tires ...Overall condition good No wear or damage Pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...
  • 2015 Kawasaki KX250F | Owners Manual - Page 33
    32 GENERAL INFORMATION j After-Race Checks After racing, first clean the motorcycle, then inspect the entire motorcycle with special attention to the air cleaner, brakes, etc. Carry out the general lubrication and make necessary adjustments.
  • 2015 Kawasaki KX250F | Owners Manual - Page 34
    Chart to keep the motorcycle in good running condition. †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer. 1. Periodic Inspection (Engine Related Item) FREQUENCY After each Every 3 races (or race (or
  • 2015 Kawasaki KX250F | Owners Manual - Page 35
    34 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 races (or race (or 2.5 hours) 7.5 hours) Every 6 races (or 15 hours) Every 12 As See races (or required Page 30 hours) - 93 43 - 43 j OPERATION Kick pedal and shift pedal - clean Engine sprocket - inspect † Coolant level - inspect
  • 2015 Kawasaki KX250F | Owners Manual - Page 36
    MAINTENANCE AND ADJUSTMENT 35 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 races (or race (or 2.5 hours) 7.5 hours) OPERATION Brake - adjust † Brake pad wear - inspect † Brake fluid level - inspect † Spoke tightness and rim runout inspect † Rear axle nut - inspect †
  • 2015 Kawasaki KX250F | Owners Manual - Page 37
    36 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 races (or race (or 2.5 hours) 7.5 hours) Every 6 races (or 15 hours) Every 12 As See races (or required Page 30 hours) - j OPERATION K Wheel bearing - inspect † K K Swingarm and UNI-TRAK linkage pivots - inspect † Swingarm and UNI-TRAK
  • 2015 Kawasaki KX250F | Owners Manual - Page 38
    MAINTENANCE AND ADJUSTMENT 37 3. Periodic Replacement (Engine and Chassis Related Item) FREQUENCY After each Every 3 Every 6 race (or 2.5 races (or 7.5 races (or 15 hours) hours) hours) OPERATION Engine oil - change Oil filter - replace K Piston and piston ring - replace K Piston pin - replace
  • 2015 Kawasaki KX250F | Owners Manual - Page 39
    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 inspection window will fluctuate depending on the
  • 2015 Kawasaki KX250F | Owners Manual - Page 40
    MAINTENANCE AND ADJUSTMENT 39 ○If no oil appears in the oil level inspection window, tip the motorcycle slightly to the right until oil is visible then return to an upright position. If no oil appears even when tipped at an extreme angle, remove the drain bolt to empty any oil that may be in the
  • 2015 Kawasaki KX250F | Owners Manual - Page 41
    40 MAINTENANCE AND ADJUSTMENT the oil filter is replaced, remove the oil fil• When ter cap bolts and take off the cap with O-ring and spring. the oil filter element with a new one. • Replace grease to the grommet. • Apply the oil filter element with the grommet to• Install ward the engine. j
  • 2015 Kawasaki KX250F | Owners Manual - Page 42
    in the table. *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds service requirements and can help to extend the life of your Kawasaki. Engine Oil Capacity Capacity: 0.75 L (0.79 US qt) (When filter is not
  • 2015 Kawasaki KX250F | Owners Manual - Page 43
    42 MAINTENANCE AND ADJUSTMENT j ○If unavailable, use equivalent engine oil in accordance with the following table. Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-30, 10W-40, 10W-50 NOTE The oil viscosity may need to be changed to accommodate atmospheric conditions in
  • 2015 Kawasaki KX250F | Owners Manual - Page 44
    MAINTENANCE AND ADJUSTMENT 43 Cooling System Check the water hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a low-pressure stream of
  • 2015 Kawasaki KX250F | Owners Manual - Page 45
    44 MAINTENANCE AND ADJUSTMENT the motorcycle perpendicular to the • Situate ground until the radiator cap is level to the ground, j • • • so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator. Remove the radiator cap in two steps. First, turn the
  • 2015 Kawasaki KX250F | Owners Manual - Page 46
    MAINTENANCE AND ADJUSTMENT 45 the radiator cap. • Install tighten the radiator shroud bolts fol• Temporarily lowing the tightening sequence. j A. Coolant Drain Bolt NOTICE Tighten the radiator shroud bolts securely. Immediately wash away any coolant that spills on the frame, engine, or wheel.
  • 2015 Kawasaki KX250F | Owners Manual - Page 47
    the air accumulated in the radiator. 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 48
    MAINTENANCE AND ADJUSTMENT 47 Spark Plug The spark plug should be taken out periodically for inspection and regapping. Measure the gap with a wire-type thickness gauge. If incorrect, adjust the gap to the specified value by bending the outer electrode. Spark Plug Gap CPR8EB-9 CPR9EB-9 If the plug
  • 2015 Kawasaki KX250F | Owners Manual - Page 49
    48 MAINTENANCE AND ADJUSTMENT • Remove the fuel tank mounting bolt and band. j A. Bolts B. Radiator Shroud A. Fuel Tank Mounting Bolt B. Band
  • 2015 Kawasaki KX250F | Owners Manual - Page 50
    MAINTENANCE AND ADJUSTMENT 49 sure to place a piece of cloth around the fuel • Be hose joint. off the dirt of the surface around the connec• Wipe tion using a cloth or a soft brush. a thin blade screwdriver into the slit on the • Insert joint lock. WARNING Fuel is flammable and explosive under
  • 2015 Kawasaki KX250F | Owners Manual - Page 51
    50 MAINTENANCE AND ADJUSTMENT the driver to disconnect the joint lock. • Turn • Disconnect the fuel hose joint from the outlet pipe. the fuel pump lead connector. • Disconnect • Remove the fuel tank. j A. Turn B. Joint Lock C. Fuel Hose Joint A. Fuel Pump Lead Connector the pipe and the fuel
  • 2015 Kawasaki KX250F | Owners Manual - Page 52
    MAINTENANCE AND ADJUSTMENT 51 the cylinder head cover around the spark • Clean plug cap hole before removing the spark plug. the spark plug cap off the plug before remov• Pull ing the spark plug. Tightening Torque Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb) the spark plug cap. • Install Pull up the
  • 2015 Kawasaki KX250F | Owners Manual - Page 53
    52 MAINTENANCE AND ADJUSTMENT sure that the dampers are in place on the • Make frame and are not damaged. If the dampers are the fuel hose joint straight onto the fuel out• Insert let pipe until the hose joint clicks. • Push the joint lock until the hose joint clicks. j not fixed completely,
  • 2015 Kawasaki KX250F | Owners Manual - Page 54
    MAINTENANCE AND ADJUSTMENT 53 and pull the fuel hose joint back and forth • Push more than two times, and make sure it is locked and does not come off. the band to the fuel tank. • Hook the fuel tank mounting bolt. • Tighten After installing fuel tank, make sure that both • throttle cables the (
  • 2015 Kawasaki KX250F | Owners Manual - Page 55
    54 MAINTENANCE AND ADJUSTMENT 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 throttle body assy, and the duct clamps and
  • 2015 Kawasaki KX250F | Owners Manual - Page 56
    MAINTENANCE AND ADJUSTMENT 55 Element Removal and Inspection • Remove the bolt on the right and left sides. the both side covers slightly outward and • Open slide the seat rearward. j A. Bolt A. Side Covers B. Seat
  • 2015 Kawasaki KX250F | Owners Manual - Page 57
    56 MAINTENANCE AND ADJUSTMENT the wing bolt, and take out the air cleaner • Remove element. NOTICE Do not twist or wring the element, as it gets easily torn or damaged. the element. If it is dirty, clean it. Also • Inspect check if the element is in good condition (no tears, hardening or shrinkage
  • 2015 Kawasaki KX250F | Owners Manual - Page 58
    MAINTENANCE AND ADJUSTMENT 57 j A. Air Cleaner Element B. Element Frame Element Cleaning and Installation the element in a bath of a high flash-point • Clean solvent or hot soapy water. Rinse the element with • clear water to remove all traces of the cleaning solution. Squeeze the element dry
  • 2015 Kawasaki KX250F | Owners Manual - Page 59
    58 MAINTENANCE AND ADJUSTMENT WARNING 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 60
    MAINTENANCE AND ADJUSTMENT 59 the air cleaner element so that its tab faces • Install upward and its projections align with the holes in the housing. the hooks of the seat under the flange collar • Insert and brackets. j A. Tab B. Projections C. Holes A. B. C. D. Hooks Seat Flange Collar
  • 2015 Kawasaki KX250F | Owners Manual - Page 61
    60 MAINTENANCE AND ADJUSTMENT the tabs of the side covers into the inside of • Install the seat, and tighten the bolts. Throttle Cable Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart.
  • 2015 Kawasaki KX250F | Owners Manual - Page 62
    MAINTENANCE AND ADJUSTMENT 61 Throttle Body Assy Idle Speed Adjustment warm up the engine. • Thoroughly Turn the idle adjusting screw/choke knob to adjust • the idle speed 2 000 ∼ 2 100 r/min (rpm) by using j the engine revolution tester (The tester should be followed by the method described by
  • 2015 Kawasaki KX250F | Owners Manual - Page 63
    62 MAINTENANCE AND ADJUSTMENT the idle speed. If so, the throttle cable may be improperly adjusted, incorrectly routed, or damaged. Be sure to correct any of these conditions before riding. Cleaning the Throttle Body Assy j WARNING Operation with damaged cables could result in an unsafe riding
  • 2015 Kawasaki KX250F | Owners Manual - Page 64
    MAINTENANCE AND ADJUSTMENT 63 the muffler clamp bolt. • Loosen the muffler mounting bolts, and pull out • Remove the muffler body rearward. the air cleaner duct clamp bolt. • Loosen the intake air temperature sensor con• Disconnect nector. j A. Muffler Clamp Bolt B. Muffler Mounting Bolts C.
  • 2015 Kawasaki KX250F | Owners Manual - Page 65
    64 MAINTENANCE AND ADJUSTMENT the intake air pressure sensor con• Disconnect nector, downstream injector connector and throttle sensor connector. sure to place a piece of cloth around the fuel • Be hose joint. off the dirt of the surface around the connec• Wipe tion using a cloth or a soft brush. a
  • 2015 Kawasaki KX250F | Owners Manual - Page 66
    MAINTENANCE AND ADJUSTMENT 65 the driver to disconnect the joint lock. • Turn • Disconnect the fuel hose joint from the outlet pipe. the upstream injector connector. • Disconnect sure to place a piece of cloth around the fuel • Be hose joint. off the dirt of the surface around the connec• Wipe tion
  • 2015 Kawasaki KX250F | Owners Manual - Page 67
    66 MAINTENANCE AND ADJUSTMENT the throttle body assy holder clamp screw. • Loosen • Pull the throttle body assy from the holder. j A. Rear Frame Mounting Bolts B. Air Cleaner Housing A. Throttle Body Assy Holder Clamp Screw
  • 2015 Kawasaki KX250F | Owners Manual - Page 68
    MAINTENANCE AND ADJUSTMENT 67 the bolts, and take off the throttle pulley • Remove cover. the decelerator cable bolt locknut, and • Loosen free the tip of cable lower end. the accelerator cable bolt, and free the tip • Loosen of cable lower end. j A. Throttle Pulley Cover Bolts B. Throttle Pulley
  • 2015 Kawasaki KX250F | Owners Manual - Page 69
    68 MAINTENANCE AND ADJUSTMENT removing the throttle body assy, cover the • After throttle body assy holder and air cleaner duct with WARNING Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition. Be sure the control cables are adjusted
  • 2015 Kawasaki KX250F | Owners Manual - Page 70
    MAINTENANCE AND ADJUSTMENT 69 the throttle body assy to the throttle body • Install assy holder. Align the projection with the groove. • Check the throttle body assy is installed securely. j A. B. C. D. Accelerator Cable Claw Decelerator Cable Bolt Decelerator Cable Bolt Locknut A. Groove B.
  • 2015 Kawasaki KX250F | Owners Manual - Page 71
    70 MAINTENANCE AND ADJUSTMENT the claw on the air cleaner duct clamp • Position between the projections. the rear frame mounting bolts to the spec• Tighten ified torque. Tightening Torque Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) the joint lock for deformation and wear. • Check the
  • 2015 Kawasaki KX250F | Owners Manual - Page 72
    MAINTENANCE AND ADJUSTMENT 71 NOTICE When installing the fuel hose joint, do not apply strong force to the delivery pipe. The pipe made from resin could be damaged. and pull the fuel hose joints back and forth • Push more than two times, and make sure they are locked and do not come off. ○If it
  • 2015 Kawasaki KX250F | Owners Manual - Page 73
    72 MAINTENANCE AND ADJUSTMENT Clutch Clutch Lever Adjustment Proper clutch lever free play is 8 ∼ 13 mm (0.3 ∼ 0.5 in.). Lever play increases with cable stretch and friction plate wear, requiring periodic adjustment. When the clutch lever free play is out of specification, first try adjusting it at
  • 2015 Kawasaki KX250F | Owners Manual - Page 74
    MAINTENANCE AND ADJUSTMENT 73 WARNING Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip
  • 2015 Kawasaki KX250F | Owners Manual - Page 75
    74 MAINTENANCE AND ADJUSTMENT • Remove the clutch cover bolts. j the clutch cover and gasket. • Remove the clutch spring bolts, clutch pressure • Remove plate and springs. A. Bolts B. Clutch Cover A. Clutch Spring Bolts B. Clutch Pressure Plate
  • 2015 Kawasaki KX250F | Owners Manual - Page 76
    MAINTENANCE AND ADJUSTMENT 75 • Remove the friction and steel plates. Steel Plate Thickness Measurement Standard 1.5 ∼ 1.7 mm (0.059 ∼ 0.067 in.) Service Limit 1.4 mm (0.055 in.) j A. Friction Plate B. Steel Plate Friction and Inspection Steel Plates Wear/Damage inspect the friction and
  • 2015 Kawasaki KX250F | Owners Manual - Page 77
    . • Install Install the friction plates and steel plates, alternat• ing between the two; be sure to start and finish with a friction plate. Service Limit 0.3 mm (0.012 in.) A. Friction and Steel Plates NOTICE A. Surface Plate B. Friction or Steel Plate C. Thickness Gauge If dry steel plates and
  • 2015 Kawasaki KX250F | Owners Manual - Page 78
    MAINTENANCE AND ADJUSTMENT 77 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. cable bracket while pushing the release shaft lever lightly forward. j A. Apply molybdenum disulfide grease. B. Push
  • 2015 Kawasaki KX250F | Owners Manual - Page 79
    78 MAINTENANCE AND ADJUSTMENT 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.)
  • 2015 Kawasaki KX250F | Owners Manual - Page 80
    MAINTENANCE AND ADJUSTMENT 79 Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. the fuel hose joint of the downstream in• Remove jector outlet pipe (see Throttle Body Assy section). the cylinder head cover bolts and cylinder • Remove head cover. j
  • 2015 Kawasaki KX250F | Owners Manual - Page 81
    80 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 82
    MAINTENANCE AND ADJUSTMENT 81 the piston to the Top Dead Center (TDC) of • Bring its compression stroke to inspect the valve clearance (the position at the end of the compression stroke) by aligning the top mark with the groove on the magneto cover while turning the crankshaft counterclockwise. this
  • 2015 Kawasaki KX250F | Owners Manual - Page 83
    82 MAINTENANCE AND ADJUSTMENT a competent mechanic following the instructions in the Service Manual. Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth.
  • 2015 Kawasaki KX250F | Owners Manual - Page 84
    cover. the head cover gasket with a new one. • Replace the head cover gasket on the cylinder head • Install cover. NOTICE Unless the upper chain guide is bottomed, the camshaft chain could push the cylinder head cover upward, leading to an oil leak. the cylinder head cover. • Install the washer
  • 2015 Kawasaki KX250F | Owners Manual - Page 85
    84 MAINTENANCE AND ADJUSTMENT • Install the two caps to the magneto cover. Tightening Torque Timing Inspection Cap: 3.5 N·m (0.36 kgf·m, 31 in·lb) Flywheel Nut Cap: 3.5 N·m (0.36 kgf·m, 31 in·lb) Exhaust System The exhaust system, in particular the muffler body, is designed to reduce exhaust noise
  • 2015 Kawasaki KX250F | Owners Manual - Page 86
    MAINTENANCE AND ADJUSTMENT 85 the muffler cover bolts. • Remove • Remove the muffler mounting bolt (rear). • Remove the muffler cover with the plastic mallet. j A. Muffler Cover Bolts B. Muffler Mounting Bolt (Rear) A. Plastic Mallet B. Muffler Cover
  • 2015 Kawasaki KX250F | Owners Manual - Page 87
    86 MAINTENANCE AND ADJUSTMENT the silencer wool with a new one. • Replace the silicone sealant attaching on the muf• Remove fler cover and muffler body. the shape of the silencer wool and install • Arrange the muffler cover to the muffler body. that the exhaust port of the muffler cover • Check
  • 2015 Kawasaki KX250F | Owners Manual - Page 88
    MAINTENANCE AND ADJUSTMENT 87 j A. B. C. D. Muffler Cover Muffler Body Muffler Cover Bolts Silicone Sealant A. Muffler Clamp Bolt B. Muffler Mounting Bolt (Front) C. Muffler Body ○If the threaded holes of the muffler cover and muffler body do not align, remove the muffler clamp bolt and muffler
  • 2015 Kawasaki KX250F | Owners Manual - Page 89
    88 MAINTENANCE AND ADJUSTMENT the tabs of the side cover into the slots of • Insert the air cleaner housing, and tighten the bolts. Rear Axle Nut inspect the rear axle nut for deformation • Visually or damage at the friction ring and caulking. If it is deformed or damaged, replace the axle nut with
  • 2015 Kawasaki KX250F | Owners Manual - Page 90
    MAINTENANCE AND ADJUSTMENT 89 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 91
    90 MAINTENANCE AND ADJUSTMENT Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and
  • 2015 Kawasaki KX250F | Owners Manual - Page 92
    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.) ○The drive system was designed for use with a DAIDO
  • 2015 Kawasaki KX250F | Owners Manual - Page 93
    92 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 94
    appears dry. Use a lubricant for drive chains. If the chain is especially dirty, clean it using a cleaner for drive chains following the instructions supplied by the chain cleaner manufacturer. NOTE inspect the sprocket teeth and replace the • Visually sprocket if its teeth are worn or damaged
  • 2015 Kawasaki KX250F | Owners Manual - Page 95
    94 MAINTENANCE AND ADJUSTMENT lubricant to the sides of the rollers so that it • Apply will penetrate to the rollers and bushings. Wipe off any excess lubricant. Adjustable Ergonomics To suit various riding positions, the handlebar holder position can be changed and the handlebar can be adjusted by
  • 2015 Kawasaki KX250F | Owners Manual - Page 96
    MAINTENANCE AND ADJUSTMENT 95 the handlebar holder nuts, washers and • Remove handlebar holders. Tightening Torque Handlebar Holder Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) j A. Handlebar Holder Nuts B. Washers C. Handlebar Holder Select the handlebar position and install the dampers into the holes
  • 2015 Kawasaki KX250F | Owners Manual - Page 97
    in one of two positions. Remove the cotter pin, pivot pin, washer, spring and footpeg. • A. B. C. D. Handlebar Clamps Clamp Bolts Gap Supporting Bar • • Do not disassemble the supporting bar on the handlebar. Check the front brake for the proper brake effect, or no brake drag. A. Cotter Pin
  • 2015 Kawasaki KX250F | Owners Manual - Page 98
    MAINTENANCE AND ADJUSTMENT 97 the washer and new cotter pin. • Install • Bend the longer end of the cotter pin. j A. Footpeg Bracket Bolts B. Footpeg Bracket a non-permanent locking agent to • Apply bracket bolts. either footpeg position and tighten • Select bracket with the two bolts. Tightening
  • 2015 Kawasaki KX250F | Owners Manual - Page 99
    98 MAINTENANCE AND ADJUSTMENT 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 brake lever position can be adjusted to suit the rider's
  • 2015 Kawasaki KX250F | Owners Manual - Page 100
    MAINTENANCE AND ADJUSTMENT 99 NOTICE 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. j With the front or
  • 2015 Kawasaki KX250F | Owners Manual - Page 101
    100 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 102
    MAINTENANCE AND ADJUSTMENT 101 Usable Brake Pad Range Steering The steering should always be kept adjusted so that the handlebars will turn freely but not have excessive play. j Steering Inspection check the steering adjustment, raise the front • To wheel off the ground using a jack (special
  • 2015 Kawasaki KX250F | Owners Manual - Page 103
    102 MAINTENANCE AND ADJUSTMENT j A. Push and Rock Steering Adjustment the front wheel off the ground using a jack • Raise (special tool: 57001-1238) and attachment (spe- A. B. C. D. Clamp Bolt Projections Number Plate • • • cial tool: 57001-1608). Unlock the clamp of the number plate. Remove
  • 2015 Kawasaki KX250F | Owners Manual - Page 104
    MAINTENANCE AND ADJUSTMENT 103 the steering stem locknut with a stem nut • Turn wrench (special tool: 57001-1100) to obtain the proper adjustment. j A. Steering Stem Head B. Steering Stem Head Nut C. Front Fork Clamp Bolts (Upper) A. Steering Stem Locknut B. Stem Nut Wrench (Special Tool: 57001-
  • 2015 Kawasaki KX250F | Owners Manual - Page 105
    oil seal, leading to an oil leak. Clean the sliding surface after each ride. 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 necessary
  • 2015 Kawasaki KX250F | Owners Manual - Page 106
    MAINTENANCE AND ADJUSTMENT 105 on your KX will get stiffer as the race progresses. Therefore, it is not recommended to increase the air pressure for additional springing. The KX forks are designed to function without added air. Rebound Damping Adjustment (Left Fork only) This adjustment affects how
  • 2015 Kawasaki KX250F | Owners Manual - Page 107
    106 MAINTENANCE AND ADJUSTMENT setting, turning it clockwise 40 or more clicks (depending on the model) is the hardest setting. Fork Oil Amount Adjustment The fork oil amount affects only the final 100 mm (4 in.) of fork travel. A higher oil amount will make the fork rebound more quickly. A lower
  • 2015 Kawasaki KX250F | Owners Manual - Page 108
    MAINTENANCE AND ADJUSTMENT 107 NOTICE Do not force the rebound damping adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. j A. Screw B. Front Fork Top Plug C. Front Fork (Right Side) Rebound Damping Adjustment (Left Fork only) the bottom of the left fork tube.
  • 2015 Kawasaki KX250F | Owners Manual - Page 109
    108 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings with a standard tip 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 110
    MAINTENANCE AND ADJUSTMENT 109 Compression Damping Adjuster Settings Spring Preload Adjustment (Right Fork only) adjust the spring preload, turn the adjuster on • To the right front fork top plug with a wrench. Adjust the spring preload to suit your preference under certain conditions. j NOTICE
  • 2015 Kawasaki KX250F | Owners Manual - Page 111
    110 MAINTENANCE AND ADJUSTMENT Spring Preload Adjuster Settings Front Fork Oil Change j • Thoroughly clean the forks before disassembly. NOTICE Be careful not to scratch the inner tube and not to damage the dust seal. Avoid scratching or damaging the inner tube or the dust seal. Use a mild
  • 2015 Kawasaki KX250F | Owners Manual - Page 112
    MAINTENANCE AND ADJUSTMENT 111 j A. Front Fork Clamp Bolts (Upper) B. 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 113
    112 MAINTENANCE AND ADJUSTMENT j A. Right Front Axle Clamp Bolts (Loosen) B. Front Axle C. Collar A. Front Fork Clamp Bolts (Lower) B. Pull down by twisting. C. Front Fork Tube the front fork clamp bolts (lower). • Loosen the front fork tubes by pulling down while • Remove twisting it. each
  • 2015 Kawasaki KX250F | Owners Manual - Page 114
    MAINTENANCE AND ADJUSTMENT 113 Left Front Fork Using the top plug wrench (special tool: 57001 -1645), remove the left front fork cylinder unit from the outer tube and slowly slide down the outer tube. • j A. Length B. Axle Holder C. Front Fork Outer Tube A. Top Plug Wrench (Special Tool: 57001-
  • 2015 Kawasaki KX250F | Owners Manual - Page 115
    114 MAINTENANCE AND ADJUSTMENT j A. Fork Oil install the left front fork cylinder unit to • Temporarily the outer tube using the top plug wrench (special tool: 57001-1645). A. Left Front Fork Cylinder Unit B. Left Front Fork Outer Tube C. Top Plug Wrench (Special Tool: 57001-1645) • Hold the
  • 2015 Kawasaki KX250F | Owners Manual - Page 116
    MAINTENANCE AND ADJUSTMENT 115 ○Protect the axle holder with a soft jaw or heavy cloth when using a vise. NOTE NOTICE When loosening the locknut, the threads of the axle holder do not touch the push rod. If the push rod is scratched, it is possible to the damage in the cylinder unit. • • j
  • 2015 Kawasaki KX250F | Owners Manual - Page 117
    116 MAINTENANCE AND ADJUSTMENT • Remove the push rod. j the fork leg from the vise. • Remove the left front fork cylinder unit with the top • Unscrew plug wrench (special tool: 57001-1645). A. Push Rod A. Left Front Fork Cylinder Unit B. Left Front Fork Outer Tube C. Top Plug Wrench (Special
  • 2015 Kawasaki KX250F | Owners Manual - Page 118
    MAINTENANCE AND ADJUSTMENT 117 the left front fork cylinder unit from the • Remove outer tube. the front fork at the inverted position for more • Hold than 20 minutes to allow the fork oil to fully drain. j A. Left Front Fork Cylinder Unit
  • 2015 Kawasaki KX250F | Owners Manual - Page 119
    the left front fork base valve assembly • Remove from the fork cylinder unit. NOTICE Disassembling the left front fork base valve assembly can lead to trouble. Do not disassemble the left front fork base valve assembly. the fork oil from the left front fork cylinder • Drain unit by pumping the
  • 2015 Kawasaki KX250F | Owners Manual - Page 120
    MAINTENANCE AND ADJUSTMENT 119 the threads of the left front fork cylinder unit • Clean and left front fork base valve assembly. j A. Fork Oil B. Left Front Fork Cylinder Unit A. Threads the piston rod fully stretched, pour 330 mL • With (11.2 US oz.) of fork oil. ○Plug the oil hole on the left
  • 2015 Kawasaki KX250F | Owners Manual - Page 121
    120 MAINTENANCE AND ADJUSTMENT the piston rod slowly several times to expel • Pump air with plugged the oil hole by finger. j A. Fork Oil B. Left Front Fork Cylinder Unit C. Oil Hole Suspension Oil SS-19 (1 L): P/No. 44091-0009 A. Pump B. Piston Rod the piston rod fully stretched, check the oil
  • 2015 Kawasaki KX250F | Owners Manual - Page 122
    MAINTENANCE AND ADJUSTMENT 121 j A. 115 ∼ 123 mm (4.53 ∼ 4.84 in.) B. Oil Level A. O-rings B. Bushings the O-rings on the left front fork base • Replace valve assembly with new ones. specified fork oil to the O-rings and bushings • Apply on the left front fork base valve assembly. the piston
  • 2015 Kawasaki KX250F | Owners Manual - Page 123
    122 MAINTENANCE AND ADJUSTMENT j A. Piston Rod B. About 20 mm (0.79 in.) C. Left Front Fork Base Valve Assembly D. Left Front Fork Cylinder Unit E. Oil Hole A. Top Plug Wrench (Special Tool: 57001-1645) B. Left Front Fork Base Valve Assembly C. Left Front Fork Cylinder Unit D. Vise the top plug
  • 2015 Kawasaki KX250F | Owners Manual - Page 124
    pressure relief screw. blow to the oil hole. 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 holes of the left front fork cylinder unit. j Tightening Torque Air Pressure Relief Screw: 1.3 N·m (0.13 kgf
  • 2015 Kawasaki KX250F | Owners Manual - Page 125
    124 MAINTENANCE AND ADJUSTMENT the piston rod end with a heavy cloth to • Protect prevent damage. the piston rod to full stroke by pushing down • Pump the left front fork cylinder unit. the piston rod for smooth operation. • Check the piston rod operation is not smooth, check the • If piston rod for
  • 2015 Kawasaki KX250F | Owners Manual - Page 126
    MAINTENANCE AND ADJUSTMENT 125 the locknut fully and measure 10 ∼ 12 mm • Tighten (0.39 ∼ 0.47 in.). wipe off the fork oil from the left front • Completely fork cylinder unit. • Insert the cylinder unit into the fork. j A. Locknut B. 10 ∼ 12 mm (0.39 ∼ 0.47 in.) A. Left Front Fork Cylinder Unit
  • 2015 Kawasaki KX250F | Owners Manual - Page 127
    126 MAINTENANCE AND ADJUSTMENT WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an accident resulting in injury. However, clamping the axle holder too tightly can damage it which will affect riding stability. Use
  • 2015 Kawasaki KX250F | Owners Manual - Page 128
    MAINTENANCE AND ADJUSTMENT 127 j A. Push Rod B. Left Front Fork Adjuster Assembly C. O-ring A. Left Front Fork Adjuster Assembly B. Locknut C. More Than 1 mm (0.04 in.) turn the left front fork adjuster assembly • Slowly clockwise until resistance is felt and check the clearance between the
  • 2015 Kawasaki KX250F | Owners Manual - Page 129
    128 MAINTENANCE AND ADJUSTMENT NOTICE When tightening the locknut, the threads of the axle holder do not touch the push rod. If the push rod is scratched, it is possible to the damage in the cylinder unit. j Tightening Torque Left Front Fork Adjuster Assembly: 69 N·m (7.0 kgf·m, 51 ft·lb) A.
  • 2015 Kawasaki KX250F | Owners Manual - Page 130
    MAINTENANCE AND ADJUSTMENT 129 j A. Top Plug Wrench (Special Tool: 57001-1645) B. Left Front Fork Cylinder Unit C. Left Front Fork Outer Tube A. Left Front Fork Outer Tube B. Fork Oil the specified amount of fork oil into the left • Pour front fork outer tube. Suspension Oil SS-19 (1 L): P/No.
  • 2015 Kawasaki KX250F | Owners Manual - Page 131
    130 MAINTENANCE AND ADJUSTMENT Right Front Fork Using the top plug wrench (special tool: 57001 -1645), remove the right front fork spring adjuster unit from the right front fork outer tube and slowly slide down the outer tube. j • A. Left Front Fork Cylinder Unit B. Left Front Fork Outer Tube C.
  • 2015 Kawasaki KX250F | Owners Manual - Page 132
    MAINTENANCE AND ADJUSTMENT 131 install the right front fork spring ad• Temporarily juster unit to the outer tube using the top plug wrench (special tool: 57001-1645). j A. Fork Oil A. Right Front Fork Spring Adjuster Unit B. Right Front Fork Outer Tube C. Top Plug Wrench (Special Tool: 57001-1645
  • 2015 Kawasaki KX250F | Owners Manual - Page 133
    132 MAINTENANCE AND ADJUSTMENT the right front fork spring preload adjuster • Turn clockwise to the hardest position. the top plug wrench (special tool: • Holding 57001-1645) with a vise, remove the right front fork spring preload adjuster on the fork spring adjuster unit with a top plug wrench (
  • 2015 Kawasaki KX250F | Owners Manual - Page 134
    MAINTENANCE AND ADJUSTMENT 133 WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an accident resulting in injury. However, clamping the axle holder too tightly can damage it which will affect riding stability. Use
  • 2015 Kawasaki KX250F | Owners Manual - Page 135
    134 MAINTENANCE AND ADJUSTMENT the locknut with a wrench and remove the • Hold right front fork bottom plug. When using the Fork Spring Compressor (Special Tool: 57001-1771): Set the fork spring compressor (special tool: 57001-1771) and a suitable jack as shown in the figure. j NOTICE When
  • 2015 Kawasaki KX250F | Owners Manual - Page 136
    MAINTENANCE AND ADJUSTMENT 135 j A. Fork Spring Compressor (Special Tool: 57001-1771) B. Heavy Cloth the holder bar of the fork spring compressor • Insert (special tool: 57001-1587) to the axle hole and secure it with the holder of the fork spring compressor (special tool: 57001-1771). A. Holder
  • 2015 Kawasaki KX250F | Owners Manual - Page 137
    136 MAINTENANCE AND ADJUSTMENT WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an accident resulting in injury. However, clamping the axle holder too tightly can damage it which will affect riding stability. Use
  • 2015 Kawasaki KX250F | Owners Manual - Page 138
    MAINTENANCE AND ADJUSTMENT 137 the outer tube with a suitable jack while • Compress keeping the front fork upright, and remove the top the right front fork spring adjuster unit, • Remove collar, spring seat and fork spring. • • plug wrench (special tool: 57001-1645). Remove the front fork from the
  • 2015 Kawasaki KX250F | Owners Manual - Page 139
    138 MAINTENANCE AND ADJUSTMENT the right front fork at the inverted position for • Hold more than 20 minutes to allow the fork oil to fully drain. • Tighten the locknut fully. j A. Locknut the fork piston rod puller adapter (special • Install tool: 57001-1791) to the threads on the fork piston
  • 2015 Kawasaki KX250F | Owners Manual - Page 140
    MAINTENANCE AND ADJUSTMENT 139 the piston rod puller to the threads on the • Install piston rod end. j A. Fork Piston Rod Puller Adapter (Special Tool: 57001-1791) B. Fork Piston Rod Puller (Special Tool: 57001-1289) A. Piston Rod Puller B. Piston Rod
  • 2015 Kawasaki KX250F | Owners Manual - Page 141
    140 MAINTENANCE AND ADJUSTMENT the fork spring, spring seat, • Install spring adjuster unit to the outer tube. collar and install the right front fork spring ad• Temporarily juster unit to the outer tube using the top plug wrench (special tool: 57001-1645). j A. Fork Spring B. Spring Seat C.
  • 2015 Kawasaki KX250F | Owners Manual - Page 142
    MAINTENANCE AND ADJUSTMENT 141 WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an accident resulting in injury. However, clamping the axle holder too tightly can damage it which will affect riding stability. Use
  • 2015 Kawasaki KX250F | Owners Manual - Page 143
    142 MAINTENANCE AND ADJUSTMENT j A. Fork Spring Compressor (Special Tool: 57001-1771) B. Heavy Cloth the holder bar of the fork spring compressor • Insert (special tool: 57001-1587) to the axle hole and secure it with the holder of the fork spring compressor (special tool: 57001-1771). A. Holder
  • 2015 Kawasaki KX250F | Owners Manual - Page 144
    MAINTENANCE AND ADJUSTMENT 143 WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an accident resulting in injury. However, clamping the axle holder too tightly can damage it which will affect riding stability. Use
  • 2015 Kawasaki KX250F | Owners Manual - Page 145
    144 MAINTENANCE AND ADJUSTMENT turn the bottom plug clockwise until resis• Slowly tance is felt and check the clearance between the j • • locknut and bottom plug for more than 1 mm (0.04 in.). Turn the locknut counterclockwise until it contacts with the bottom plug. With the bottom plug held
  • 2015 Kawasaki KX250F | Owners Manual - Page 146
    MAINTENANCE AND ADJUSTMENT 145 When not using the Fork Spring Compressor (Special Tool: 57001-1771): Apply a non-permanent locking agent to the threads of the bottom plug. Compress the outer tube by hands and remove the top plug wrench (special tool: 57001-1645). the outer tube with a suitable jack
  • 2015 Kawasaki KX250F | Owners Manual - Page 147
    146 MAINTENANCE AND ADJUSTMENT WARNING If the axle holder is not securely clamped, the front fork assembly may come out of the vise when compressed, which could cause an accident resulting in injury. However, clamping the axle holder too tightly can damage it which will affect riding stability. Use
  • 2015 Kawasaki KX250F | Owners Manual - Page 148
    MAINTENANCE AND ADJUSTMENT 147 the right front fork spring preload adjuster so • Install that the projections align to the holes on the fork spring adjuster unit. j A. Threads B. O-ring C. Right Front Fork Spring Preload Adjuster A. Projections B. Holes C. Right Front Fork Spring Adjuster Unit
  • 2015 Kawasaki KX250F | Owners Manual - Page 149
    148 MAINTENANCE AND ADJUSTMENT the specified amount of fork oil into the right • Pour front fork outer tube. j A. Top Plug Wrench (Special Tool: 57001-1645) B. Right Front Fork Spring Preload Adjuster C. Right Front Fork Spring Adjuster Unit D. Top Plug Wrench (Special Tool: 57001-1705) A. Right
  • 2015 Kawasaki KX250F | Owners Manual - Page 150
    MAINTENANCE AND ADJUSTMENT 149 SOFT (K = 9.2 N/mm) HARD (K = 10.0 N/mm) Standard Oil 232 mL (7.84 US Amount oz.) Adjustable Range 227 ∼ 375 mL (7.67 ∼ 12.7 US oz.) j Standard Oil 214 mL (7.24 US Amount oz.) Adjustable Range 209 ∼ 357 mL (7.07 ∼ 12.1 US oz.) the O-ring on the spring adjuster unit
  • 2015 Kawasaki KX250F | Owners Manual - Page 151
    150 MAINTENANCE AND ADJUSTMENT Tightening Torque Front Fork Clamp Bolts (Lower): 22 N·m (2.2 kgf·m, 16 ft·lb) the left front fork cylinder unit and right • Tighten front fork top plug using the top plug wrench (special tool: 57001-1645) to the specified torque. j ○The torque of left front fork
  • 2015 Kawasaki KX250F | Owners Manual - Page 152
    MAINTENANCE AND ADJUSTMENT 151 a non-permanent locking agent to the front • Apply fork clamp bolts (upper). the front fork clamp bolts (upper) to the • Tighten specified torque. Tightening Torque Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) the front wheel assembly between the fork •
  • 2015 Kawasaki KX250F | Owners Manual - Page 153
    clamp bolts to the spec• Tighten ified torque. Tightening Torque Right Front Axle Clamp Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb) 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 154
    MAINTENANCE AND ADJUSTMENT 153 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 155
    154 MAINTENANCE AND ADJUSTMENT Rear Suspension (UNI-TRAK®) 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 156
    MAINTENANCE AND ADJUSTMENT 155 Rebound Damping Adjuster Settings NOTICE Do not force the rebound damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. j ○Adjustment of the rebound damping adjuster for NOTE the rear suspension will slightly affect
  • 2015 Kawasaki KX250F | Owners Manual - Page 157
    156 MAINTENANCE AND ADJUSTMENT High Speed Compression Damping Adjuster Settings j A. Compression Damping Adjuster for High Speed B. Compression Damping Adjuster for Low Speed If the damping feels too soft or too stiff, adjust it in accordance with the following table. A. Seated Position (
  • 2015 Kawasaki KX250F | Owners Manual - Page 158
    MAINTENANCE AND ADJUSTMENT 157 Low Speed Compression Damping Adjuster Settings NOTICE Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. j ○Adjustment of the compression damping adjuster NOTE for the rear suspension
  • 2015 Kawasaki KX250F | Owners Manual - Page 159
    158 MAINTENANCE AND ADJUSTMENT the hook wrench (special tool: 57001 • Using -1539), turn the spring preload adjusting nut as required. Turning the adjusting nut down increases the spring preload. j A. Spring Preload Adjusting Nut B. Locknut C. Hook Wrenches (Special Tools: 57001-1101, 1539) A.
  • 2015 Kawasaki KX250F | Owners Manual - Page 160
    MAINTENANCE AND ADJUSTMENT 159 K = 53 N/mm* (K = 5.4 kgf/mm) K = 55 N/mm (K = 5.6 kgf/mm) *: Standard 125.8 ∼ 139.5 mm (4.95 ∼ 5.49 in.) 125.8 ∼ 139.6 mm (4.95 ∼ 5.50 in.) making the adjustment, move the spring up • After and down to make sure that it is properly seated. the rear frame with air
  • 2015 Kawasaki KX250F | Owners Manual - Page 161
    160 MAINTENANCE AND ADJUSTMENT Wheels Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track conditions and rider preference, but keep it close within the recommended range. To check the tire air pressure, remove the air valve cap, and make sure to
  • 2015 Kawasaki KX250F | Owners Manual - Page 162
    MAINTENANCE AND ADJUSTMENT 161 ○The NOTE welding spot of the rim may show excessive runout. Disregard this when measuring rim runout. j Rim Runout A. Bead Protector Nut Rim Runout • • Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout. The difference
  • 2015 Kawasaki KX250F | Owners Manual - Page 163
    162 MAINTENANCE AND ADJUSTMENT 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 164
    MAINTENANCE AND ADJUSTMENT 163 Tightening Torques 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. Location of nuts and bolts j 1. 2. 3. 4. 5. 6. Front
  • 2015 Kawasaki KX250F | Owners Manual - Page 165
    164 MAINTENANCE AND ADJUSTMENT j 1. 2. 3. 4. 5. 6. Steering Stem Head Nut Front Master Cylinder Clamp Bolts Steering Stem Nut Handlebar Holder Nuts Rear Master Cylinder Mounting Bolts Rear Brake Disc Mounting Bolts 7. 8. 9. 10. 11. Rear Axle Nut Rocker Arm Pivot Nut Tie-Rod Mounting Nuts Rear
  • 2015 Kawasaki KX250F | Owners Manual - Page 166
    MAINTENANCE AND ADJUSTMENT 165 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 may become
  • 2015 Kawasaki KX250F | Owners Manual - Page 167
    166 MAINTENANCE AND ADJUSTMENT Fastener Handlebar Holder Nuts Steering Stem Head Nut Steering Stem Nut Rear Frame Mounting Bolts N·m 34 98 4.9 34 kgf·m 3.5 10 0.50 3.5 ft·lb 25 72 43 in·lb 25 Remarks R j AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G:
  • 2015 Kawasaki KX250F | Owners Manual - Page 168
    -based window cleaners. j WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around
  • 2015 Kawasaki KX250F | Owners Manual - Page 169
    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. After washing use a soft cloth to gently dry plastic parts. When dry, treat the non-painted plastic parts with an approved
  • 2015 Kawasaki KX250F | Owners Manual - Page 170
    MAINTENANCE AND ADJUSTMENT 169 If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner/treatment to clean and care for leather accessories. Washing leather parts with detergent and water will damage them, shortening their life. Vinyl parts should be washed with
  • 2015 Kawasaki KX250F | Owners Manual - Page 171
    170 MAINTENANCE AND ADJUSTMENT Brake Pedal • Rear Master Cylinder Joint Pin • Rear Pedal • Kick Footpeg • • Shift Pedal j Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch Cable Throttle Cable • •
  • 2015 Kawasaki KX250F | Owners Manual - Page 172
    chain appears dry. Use a lubricant for drive chains. If the chain is especially dirty, clean it using a cleaner for drive chains following the instructions supplied by the chain cleaner manufacturer. Apply lubricant to the sides of the rollers so that it will penetrate to the rollers and bushings
  • 2015 Kawasaki KX250F | Owners Manual - Page 173
    172 MAINTENANCE AND ADJUSTMENT DFI Self-Diagnosis This motorcycle equips the DFI trouble self -diagnosis system. Trouble diagnosis can be conducted with the optional parts sold separately as the following procedures. Self-diagnosis Outline The self-diagnosis has two modes and can
  • 2015 Kawasaki KX250F | Owners Manual - Page 174
    MAINTENANCE AND ADJUSTMENT 173 Dealer Mode The orange FI warning indicator light emits service code(s) to show the problem(s) which the DFI system, and ignition system has at the moment of diagnosis. Self-diagnosis Procedures Disconnect the capacitor lead connector. • j A. Capacitor Lead
  • 2015 Kawasaki KX250F | Owners Manual - Page 175
    174 MAINTENANCE AND ADJUSTMENT the power supply harness (optional part: • Connect 26011-0246) to the capacitor lead connector of the j • • main harness. Connect the power supply harness (optional part: 26011-0246) to the 12 V battery. Connect the O/Y lead (red cap) to the positive (+) terminal
  • 2015 Kawasaki KX250F | Owners Manual - Page 176
    terminal for more than 2 sec- • onds, and then keep it grounded continuously. Count the blinks of the orange light to read the service code. Keep the lead ground until you finish reading the service code. j A. Orange Launch Control Mode/FI Warning Indicator Light B. Self-diagnosis Terminal
  • 2015 Kawasaki KX250F | Owners Manual - Page 177
    a number of problems, all the service codes can be stored and the display will begin • startingthere from the lowest number service codes in the , the there is no problem, no code and unlight. • If For example, if two problems occurred in the order of 21, 12, the service codes are displayed from •
  • 2015 Kawasaki KX250F | Owners Manual - Page 178
    177 ○Even if the battery or the ECU is disconnected, or the problem is solved, all service codes remain in the ECU. Service Code Table Service Code 11 12 13 14 21 25 31 41 42 Orange FI Warning Indicator Light Problems Throttle sensor malfunction, wiring open or short Intake air pressure sensor
  • 2015 Kawasaki KX250F | Owners Manual - Page 179
    j ○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU (see Service Manual). ○When no service code is displayed, the electrical parts of the
  • 2015 Kawasaki KX250F | Owners Manual - Page 180
    is not exhaustive and 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 - NOTE Engine does not turn over: Valve seized Valve lifter seized
  • 2015 Kawasaki KX250F | Owners Manual - Page 181
    180 TROUBLESHOOTING GUIDE head warped • Cylinder gasket damaged • Cylinder • Decompression trouble Poor low-speed performance plug damaged • Cylinder head head warped • Cylinder gasket • Decompression damaged trouble • defective • ECU Brake • Clutch dragging • Engineslipping overheating • Engine
  • 2015 Kawasaki KX250F | Owners Manual - Page 182
    TROUBLESHOOTING GUIDE 181 Fuel/air mixture incorrect: Air cleaner element clogged, poorly clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder gasket damaged Decompression trouble Improper acceleration: Throttle valve does not fully open Air cleaner element clogged Fuel
  • 2015 Kawasaki KX250F | Owners Manual - Page 183
    182 TROUBLESHOOTING GUIDE Lubrication inadequate: Engine oil level too low Engine oil quality poor 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 184
    TROUBLESHOOTING GUIDE 183 Engine noise abnormal Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating ECU defective chain, sprocket, chain guide worn • Camshaft spring broken • Decompression Flywheel magneto loose • Abnormal
  • 2015 Kawasaki KX250F | Owners Manual - Page 185
    184 TROUBLESHOOTING GUIDE Rear shock absorber noise: Shock absorber damaged j Disc brake tightened Exhaust smoke Excessively white: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner element clogged Brownish: Air cleaner
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    TROUBLESHOOTING GUIDE 185 Shock absorption unsatisfactory (suspension too soft): Front fork oil level insufficient and/or front fork leaking oil Front fork oil viscosity too low Front
  • 2015 Kawasaki KX250F | Owners Manual - Page 187
    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
  • 2015 Kawasaki KX250F | Owners Manual - Page 188
    Too Hard Spring too stiff: Rebound or compression damping improperly adjusted. Spring too hard Fork oil amount too high Troubleshooting Improper Settings j A. Weight B. Fork Stroke C. Increase Amount D. Standard Oil Amount E. Decrease Amount Changing the fork oil amount works effectively
  • 2015 Kawasaki KX250F | Owners Manual - Page 189
    188 TUNING too soft • Springs oil deteriorated • Fork and/or compression damping improperly • Rebound adjusted. • Spring preload too soft Rear shock absorber improper adjustment symptoms Too Hard Suspension too stiff: Compression damping too high Spring too hard Hence, if the actual rider weighs
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    TUNING 189 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 191
    and the rider's preferences. the fork oil amount. • Decrease a softer spring, or decrease • Use preload. the 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 or rebound
  • 2015 Kawasaki KX250F | Owners Manual - Page 192
    TUNING 191 the rebound damping. • Increase the rear shock absorber spring preload. • Decrease Decrease the compression damping. • 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 amount.
  • 2015 Kawasaki KX250F | Owners Manual - Page 193
    192 TUNING 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 194
    TUNING 193 Special Care According to Track Conditions dry, dusty conditions (such a volcanic ash or • In fine powdery dust), special care must be given to • • • • • keeping the air cleaner element clean. When riding on wet, heavy clay, mud adheres to the tires and other parts of the vehicle. The
  • 2015 Kawasaki KX250F | Owners Manual - Page 195
    the engine operation data in a personal computer (PC). KX FI Calibration Kit: Part No. - 99999-0394 For details, refer to the KX FI Calibration Kit manual.
  • 2015 Kawasaki KX250F | Owners Manual - Page 196
    • If 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. Clean the sliding surface of the front fork and rear shock absorber. Maintenance After Riding in the Rain
  • 2015 Kawasaki KX250F | Owners Manual - Page 197
    196 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE grease to swingarm and rear suspension • Apply pivots. 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 198
    STORAGE 197 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
  • 2015 Kawasaki KX250F | Owners Manual - Page 199
    198 STORAGE After Storage the plastic bag from the muffler. • Remove Make sure the spark plug is tight. • the fuel tank with fuel. • Fill all the points listed in the Daily Pre-Ride • Check Checks section. a lubrication procedure in the Lubrication • Perform section. ○Fit the plug cap securely
  • 2015 Kawasaki KX250F | Owners Manual - Page 200
    ENVIRONMENTAL PROTECTION 199 ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle, please follow these Tread
  • 2015 Kawasaki KX250F | Owners Manual - Page 201
    200 WIRING DIAGRAM WIRING DIAGRAM
  • 2015 Kawasaki KX250F | Owners Manual - Page 202
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