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`11 KX250YBF Main Specifications

1. ROTOR 21007 0133 21007 0155 REGULATOR VOLTAGE 21066 0042 Newly specified due to employment of FI system CAPACITOR 21013 0001 Newly specified due to employment of Fl system 11056 0001 Used to mount the capacitor 132BA0610 Used to mount the capacitor Used to mount the rotor from M10 to M12 Used to mount the stator Used to mount the crankshaft sensor Used to mount the regulator Used to mount the regulator O0OO0O0O000O0O0O0O0DO Ref Frame Fittings Ref Frame Ref Frame Fittings Ref Frame Fittings Ref Crankshaft 21007 A B ReT Engine Cover s DFI System of 2011 Model KX250F Differences between Carburetor and DFI Digital Fuel Injection System The Digital Fuel Injection DFI system detects the airflow rate air temperature and air pressure based on various sensor information This system can provide more precise control of the air fuel ratio than the carburetor even when air density and other parameters change Also the system can improve the throttle response as it delivers fuel without using a negative intake air pressure E Carburetor system E DFI system Detects the intake airflow Detects the throttle opening intake air pressure and engine Determines the fuel rate speed using sensors Fe
2. O S 11 gt 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance cdr lcd Inter 10 part 11 part Modifications 2 ee ED USE 14031 0098 14031 0115 Due to redesigned generator PLUG 92066 0039 92066 0153 The groove depth has been changed O PLUG 92066 0150 92066 0133 a ane Aaa a Ne CLAMP 92171 0195192173 0058 aa redesigned generator harness 92055 920654 Throttle Modifications from 10 KX250XAF to 11 KX250YBF O 111 gt 10 interchangeable 3 Others O S 11 gt 10 interchangeable as a KX250Y 2 Reliability improvement 1 Performance eN Inter 10 gt 11 part Modifications dt A throttle assembly with 43 mm diameter bore has THROTTLE ASSY od a 0154 been newly specified due to employment of Fl x system A new harness has been specified due to employment of Fl system CLAMP 92037 1993 For harness x O 16183 HARNESS 26031 0782 92172 21176A AR 921728 Ng 21176 Fuel pump Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeab
3. 1 Performance improvement change Engine bracket upper LH 32190 0391 32190 0477 The material and thickness have been changed From Os aluminum t8 to iron t4 5 Engine bracket upper RH 32190 0392 32190 0478 The material and thickness have been changed From Os aluminum t8 to iron t4 5 Engine bracket front 32190 0431 32190 0461 The material and thickness have been changed From Os aluminum t6 to iron t4 5 Bolt upper M8 130CA0818 92154 0380 FromMBx18toMBx14 o OS Bolt upper M10 92153 0802 92154 0381 FromM10x35toM10x32_ OL OS Blot front M8 92153 1916 92154 0378 From M8 x 102toMBx98_____JO OS Blot front M10 92153 1917 92154 0518 From M10 x 104 to M10x100 FO OS 32190B Ref Cylinder Head 92154B 32190 92154A 92154B Ref Frame 92154A Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a e O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change El eign nan NS 11056 0505 Newly specified due to employment of Fl system lol Bracket ECU 11055 1474 11056 0069 Changed from igniter to ECU due to employment of Fl system O x pa ls 132BA0610 Newly specified due to employment of Fl system fof Bolt ECU bracket Pf 9253 1628 tox Bracket regulator ee e 11055 1542 T 1 lol 1 lol 1 jot x EA poz lt lt 1
4. K 51 N mm 92145 0463 Yellow painted 11M Standard K 52Nimm 92145 0321 Blue painted HARD K 53 9 N mm 92145 0347 Red painted HARD KX250X Right Fork Oil Flow Model Slide bushing SHOWA Fully stretched when rebound spring is compressed E ae Maximum length Guide bushing Restrictor Free piston Generates an outer cylinder damping force pee et Oe I O Pressure spring Middle stroke O e PPP n D Be rT A eriba o Air chamber Minimum length Sub piston Main piston Main spring Oils bb dE EMO ol D 7 ee i i i I pe eT 0000 cos O Prevents a bottom impact Slide pipe fully compressed when top end contacts SFF KX250Y Left Fork Oil Flow Model Slide bushing Guide bushing SHE E mu Fully stretched when rebound spring is compressed Maximum length Restrictor Generates an outer cylinder Pressure spring damping force Middle stroke Air chamber ae A nate ed Sub piston Main piston Minimum length No main spring No sliding friction Oils Prevents a bottom impact Slide pipe fully compressed when top end contacts SFF KX250Y Right Fork Oil Flow Model PP Fully stretched when rebound spring is compressed Guide bushing Maximum length Slide bushing 00000 0O 00 Middle stroke Preload adjuster 1 5 to 8 5 Y MA E e o Compression strokefa 9
5. Counterclockwise from Counterclockwise from n the fully seated position the fully seated position side MIES rerun torana 8 click return total 19 click Low speed click damping force damping force adjustment adjustment Optional Parts EU BR 1 Wheels 1 1 Front wheel Iron nipple 41032 1077 Wheel subassembl 41090 0114 1 2 Rear wheel Iron nipple 41032 1085 Wheel subassembly 41090 0105 2 Sprocket Number of teeth Number of teeth 471 42041 1447 42041 1382 481 42041 1448 42041 1383 Aluminum 49T STD 42041 1449 42041 1384 50T 42041 1450 42041 1408 51T 42041 1451 42041 1428 3 Brake disc No petal disc hole 41080 0193 Rear T 41080 0094 4 Springs 4 1 Fork spring i Standard oil Spring rate N mm Oil level adjusting range cm a Part amount cm K 8 7 130 to 508 44026 0156 K 9 5 130 to 492 155 44026 0157 4 2 Shock spring Spring rate N mm Initial adjusting range mm K 47 125 8 to 139 3 92145 0464 K 49 125 8 to 135 8 92145 0465 K 53 125 8 to 139 5 92145 0466 5 Handle holder Holder upper For 28 6 mm dia 46012 0020 Holder lower For 28 6 mm dia 46012 0021 Holder lower For 22 2 mm dia 46012 0048 Identifying the KX250Y Suspension Springs 1 Front fork Part Spring rate Spring length N mm Standard Optional mm A A gt O ae A ae ae 2 Rear shock absorber Part Spring
6. E See i E F UG O _ 8 08 6 6 OO 6 8 6 0 0 6 6 0 6 6 6 606 6 0 6 9 6 0 6 60 06 8 amp iad Ln n Tema bms am as a Reduced friction by integrated spring Spring preload adjustment Increased setting range Reduced friction between parts Improved ridini li Conventignal system Conventional ys i system FACUON Cha Compression ES ad Friction N Approx 25 of reduction vaa Extension You can adjust the height without changing the posture Stroke mm 8 Modifications of 2011 Model Suspension System SHOWA 2 Rear suspension Features Optimized damping force according to the improved traction by fuel injection FI system 9 Information about 2011 Model Suspension System SHOWA 1 Front forks United States European Japanese model model model Rebound tension Adjustingrange range Total number of clicks 20 4 damping Standard number of adjuster clicks MAX 10 MAX 12 MAX 10 Adjusting range Total number of clicks 22 6 Compression side Standard number of adjuster clicks MAX 7 MAX 9 MAX 7 Adjusting range Total number of clicks 60 6 Preload Standard number of adjuster clicks MIN 22 MIN 28 MIN 24 Q Right 3 Oil amount adjusting range ml RA to 500 O Standard oil amount ml ae ee Left Outer cyl
7. Modification 2 Modification 1 2010 model 2011 model Rotation angle 53 1 degrees 60 0 degrees Modification 2 2010 model 2011 model Length 19 5 mm TO 2010 model 2011 model O Kick Modification 3 e The spring length has been changed Modification 1 to improve parts assembly efficiency Reduced insertion t margin Modification 1 2010 model 2011 model Length 16 9 mm 17 4 mm Modification 1 O Radiator 2011 model e A capacitor has been added to the left side of the radiator after the DFI module was installed Capacitor AA DRAMA PATATA TT a PASA TARA O DFI System Operating without Battery Power e Outline The same DFI system that is operated without battery power as that of the KX450F 2010 year model is used When kick starting the ECU startup time is reduced to facilitate easy starting of the engine When compared with carburetor models you do not need to operate the hot starter lever when restarting You can start the engine more easily using the kick lever on the 2011 model Compression TDC Exhaust TDC Compression TDC Exhaust TDC lst rotation 2nd rotation 3rd rotation Ath rotation 5th rotation Compres Combus sion tion Compres Combus sion tion t Compres sion Exhaust Intake Exhaust Intake Engine startup Fuel injection t i i gt nition gt nition l i Y Number of rotations
8. Quick throttle response by the new Progressing Eli 2 Link mechanism Th Weights approximately 600 g half of the carburetor system Fuel Pump z A cover has been added to the fuel inlet This Module FPM il ensures stable fuel delivery even when the fuel level changes significantly The new aluminum body contributes to a reduction in weight to approximately 570 g Features of Motocrosser DFI System ECU DFI System Operating without Battery Power E Background and use of DFI system Wiring Diagram between ECU and Primary operating without battery power Components Compared with the carburetor system the conventional DFI system consumed a larger Il amount of current The mounted battery was rectas necessary because the battery power is required to supply electric power to the DFI system when the engine starts Regulate l l Crankshaft sensor ECU power supply However in order to reduce weight our 2011 model does not have a battery it receives all i i rottle position sensor required electric power for the DFI system from menes sensor In general the ACG power is proportional to the engine speed The kick start may not sensor increase the engine speed and the electric ECU power supplied from the ACG may be insufficient sensor The new DFI system has a Power Delivery function that can minimize current Jamas consumption during engine startup by the ECU Ignition coil The engine s
9. in l _ 7 Suspension System Setting Preparation before setting 1 When you set the suspension be sure to check the adjuster position and sag data correctly gt We suggest that you record them them on a setting chart and others gt When you compare the data with the past log you can easily identify the current problem 2 If you have checked the remaining suspension stroke while riding you can determine the setting softer or harder and determine the front and rear balance of the motorcycle 3 If you roll the motorcycle or have another type of accident check the suspension system and each fastener carefully 4 The following provides typical examples for when you are talking with a rider You can answer as follows Example of a suspension setting chart 7 Suspension System Setting SHOWA Settings for straight line riding e The tension TEN damping force is too high and e Increase the effective stroke by reducing the tension TEN damping force packed T 1 e Too low and hard at the braking gap e The stroke is large due to the poor reaction e Add oil to increase the pressure and the effective stroke e Raise the stroke position by increasing the initial force of the main spring T 1 Too hard in an intermediate area at the braking gap e The main spring is too rigid e Reduce the main spring rate e The BCV is too hard e Set the BCV correctly see the sep
10. 43015 Ref Frame Ref Swingarm Modifications from 10 KX250XAF to 11 KX250YBF O S 11 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement A arD 11 part Modifications change Not modified OPTION O 11 10 interchangeable 3 Others Kx250Y 2 Reliability improvement 1 Performance improvement T Inter Lever assembly grip 46076 0034 46076 0019 Use of the hot starter lever has been stopped BEDEN li fol Modifications from 10 KX250XAF to 11 KX250YBF o A IM asa 49006 OPTION Modifications from 10 KX250XAF to 11 KX250YBF Ca e ae anes a e O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Damper assembly LH 44071 0647 44071 0746 The structure has been changed SFF damper leg JPN Ol fox Fork bolt comp 92154 0271 92154 0542 The valve specifications have been changed JPN Ol Jf fox Bamper asec 44071 0649 44071 0708 1 x cartridge Pipe fork outer 44008 0047 44008 0016 The degree of rigidity has been changed Ol xo Pipe fork inner LH 44013 0147 44013 0165 The structure has been changed SFF damper leg IO i y D 44071 N H 44008 92154B 44008 C D 32085 2 E 440267478 D 2 EN 46102A 44013A 44013 430589 Y lf Bh D5
11. O J an ee ED ifs eat N Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a st O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement Part name 10 part 11 part Modifications change The structure has been changed Damper assembly LH 44071 0647 44071 0695 SEF damper leg US CN AU of fF Fork bolt comp 92154 0271 92154 0411 The valve specifications have been changed US CN AU rot x En 44071 0649 44071 0708 1 x cartridge Pipe fork outer 44008 0047 44008 0016 The degree of rigidity has been changed FO fox Pipe fork inner LH 44013 0147 44013 0165 The structure has been changed SFF damper leg rot x y N ly 44008 921548 C gt 32085 2 E a0026 A 8 e 2 o 46102A 44013 4305899 Y ole ee ES A 4 A 4 Modifications from 10 KX250XAF to 11 KX250YBF a aa O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Damper assembly LH 44071 0691 44071 00744 The structure has been changed SFF damper leg EU BR O x Fork bolt comp 92154 0371 92154 0549 The valve specifications have been changed EU BR Ol x cartridge Pipe fork outer 44008 0047 44008 0016 The degree of rigidity has been changed Ol fox Pipe fork inner LH 44013 01
12. Others KX250Y 2 Reliability improvement 1 Performance An Range CYLINDER ENGINE 11005 0127 11005 0138 The height has been changed from 36 5 to 36 3 OS Top surface has been reshaped and drilled hole on PISTON ENGINE 13001 0115 13001 0125 ihe borhas bse dieuesd OS Air cleaner O S 11 10 interchangeable as a Modifications from 1 0 KX250XAF to 11 KX250YBF O 11 10 interchangeable 3 Others ae 2 Reliability improvement 1 Performance Ce ee ART e Pare Modifications DEBES change The guard has been reshaped to support intake air CASE AIR FILTER 11011 0157 11011 0156 temperature sensor HOLDER 13280 0108 13280 0383 The holder mount has been reshaped ane The volumetric capacity has been increased to support installation of intake air temperature sensor 92153 0863 92150 1506 The surface treatment has been changed Redesigned due to modification from cab to throttle body 14073 0270 14073 0291 92171 0651 92171 1990 132804 Ref Frame Muffler O S 11 10 interchangeable as a a Modi
13. by single kick Electricity is supplied to the ECU fuel pump and injector in that order If the engine is already warm it can be started a single kick You can start the engine by rotating the crankshaft 3 times e DFI system components The ECU processes the following sensor information and controls each actuator Actuator Fuel pump a o ate E I I I L I I I I I L I I I I L I I y a a e 5 ya a N z O N O 5 O jee ee ee ee ee ee ee ee ee ee ee E O ee ee ee ee ee ew e Mounting position of each sensor Vehicle down sensor Intake air temperature sensor ZASE SERSA LT e Throttle body The throttle body having the bore diameter of 43 mm is used This is similar to the one mounted on the KX450F This throttle body contains two link shafts progressive throttle link see Note 1 and allows the air flow that is equivalent to the FCR carburetor in a small ee throttle opening When the throttle 1s opened more than 3 8 it opens even E q xa quicker to provide a sharp response and a sensation of power T K 2 Se e Injector Fuel injection has been set according to the engine characteristics The fuel injection capacity 1s approximately 20 higher than that of the KX450F model e Fuel pump The same fuel pump as that of the KX450F 2009 year model is used As the fuel level chan
14. nn Thickness 6 0 mm 9 0 mm e The overall length has been changed and the rear caliper holder mount has been changed Modification 1 KX450F parts are commonly used on the 2011 model and later Modification 1 2010 model AAA LAS PILI LS Sprocket and drive chain e Final gear ratio The final gear ratio has been changed according to the engine characteristics Modification 1 2010 model 2011 model Reduction gear 13 48 13 50 ratio e Drive chain The number of links has been changed due to the change of the reduction gear ratio Modification 2 2010 model 2011 model Modification 2 Modification 1 pubes 112 links 114 links links O Seat 2011 model e The left and right rubber seat surfaces have been changed to improve the hold characteristics The KX450F 201 1 year model was also modified ina similar way sess SR Changed O Engine brackets e The material thickness and mounting bolts of the front and rear engine brackets have been changed in order to optimize the rigidity balance for better rear traction front gripping force and cornering performance 2011 model Front 2010 model 2011 model Material Aluminum Iron Thickness 6 0 mm 4 5 mm Front side Mounting bolt M8 x 102 mm M8 x 98 mm M8 x 104 mm M8 x 100 mm Rear 2010 model 2011 model Material Aluminum Iron Thickness 8 0 mm 4 5 mm Mou
15. the assembly process Wipe it a few times and the oil leaks will stop MW Check to see that the slider section such as the slide pipes is free of dents and rust gt If a seal is damaged it may lead to an oil leakage gt After riding always check to see that the slider section is free of dents WE All nuts and bolts must be tight at the axle tightening part and the outer tube tightening part If any fasteners are loose rideability may be significantly reduce and in the worst scenario the motorcycle may roll over MW The upper and lower brackets and the axle holder must be free of damage Damages to these areas should not occur if the motorcycle is operated correctly However these points must be checked carefully as those damages may be fatal to humans If a turnover or other accidents occurred in particular they must be inspected very carefully MW The suspension system must operate smoothly A bent slide pipe or other problems caused by a roll collision or other accidents must be checked gt Because the slide pipe is made up of thin material do not repair or reuse it if it is bent All parts must be reassembled carefully If they are assembled using an incorrect axis distance or if the fork is twisted due to a roll or other accident the suspension system will not operate normally Before riding be sure to check the operation of the suspension system for example check the operation of the front forks while you sit on the seat E Aft
16. 0 interchangeable as a ot Modifications from 10 KX250XAF to 11 KX250YBF 0 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement gi 1 Performance A da i Inter Part name 10 part 11 part Modifications change CRANKSHAFT COMP 13031 0136 13031 0143 The inertia moment has been changed x x CRANKSHAFT LH 13037 0164 13037 0170 The inertia moment has been changed CRANKSHAFT RH 13037 0165 13037 0171 The inertia moment has been changed 13031 Ref Generator 13037A Clutch O S 11 gt 10 interchangeable as a Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others 2 Reliability improvement KX250Y_ 1 Performance ee Inter 10 part 11 part Modifications le ls change Not m modified Starter kick O S 11 gt 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others Engine KX250Y 2 Reliability improvement 1 Performance improvement ae a Inter Part name 10 part 11 part Modifications change SPRING 92145 0051 92145 0811 The insertion margin to
17. 00 E Integrated main spring For lubrication only Slide pipe fully compressed when top end contacts
18. 0047 44008 0016 The degree of rigidity has been changed JO x Pipe fork inner RH 44013 0148 44013 0164 The structure has been changed SFF damper leg JO x Bolt center boltcomp____ 92154 0409 The structure has been changed SFF damperleg JO 0000000 O rat 43058 _9 Modifications from 10 KX250XAF to 11 KX250YBF O 5 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Holder fork upper 44039 0079 44039 0103 The fork offset has been changed From 23 5 to 22 5 OL gt x Holder fork under gt pesar to fpop Bolt upper holder 92153 1399 92154 0463 The surface treatment has been changed OL gt x Bolt under holder 92153 0990 92154 0464 ETT O 44071 92154A E 5141 _ i T T 44026 A B 0090000 0 MO 0000 DD q ii 43058 _9 Modifications from 10 KX250XAF to 11 KX250YBF O 5 11 gt 10 interchangeable as a l O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement See ae q change lo I lo Tank comp fuel 51001 0262 51001 0305 Redesigned parts for FI system x Cap assembly 51048 0009 51048 0031 Use of new design and mechanism Modifications from 10 KX250XAF to 11 KX250YBF i asa et O 11 10 interchangeable 3 Others KX250Y 2 Reliab
19. 0YBF O S 11 gt 10 interchangeable as a eh O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement eas 11 part Modifications EET change C A E Patter shroud lower 56069 0036 560890899 1 TO Pattern shroud upper R 56054 0466 56088 9900 1 TOA Pattern shroud lower R 66069 0037 560889801 1 J x Mark sidecover 86054 0589 5059 0888 1 TT Qe Ref Radiator Ref Radiator Ref Side Covers Modifications from 10 KX250XAF to 11 KX250YBF Se gt TO Miarchangeabis asa eh O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement a Inter Bolt M6 92153 0503 92150 1435 The surface treatment has been changed EOL oO Suspension Specifications Standard 1 Front fork 1 1 Fork extrusion amount 1 2 Spring settings Japanese model United States model European model 7 mm United States model Japanese model European model Spring rate N mm K 9 1 RH Initial adjustment MIN 24 click total 60 click adjustment MIN 22 click total 60 click adjustment MIN 28 click total 60 click adjustment Initial setting mm 2 5mm 2 2 mm 3 2 mm 1 3 Damping force adjustment United States model Japanese model European model 10 click return total
20. 20 12 click return total 20 damping force adjustment Rebound tension damping click damping force click damping force adjustment adjustment l 7 click return total 22 click 9 click return total 22 click Compression side damping force adjustment 1 4 Volume of hydraulic oil and oil level adjustment range Inside of damper comp United States model Japanese model European model Oil amount cm 260 lt lt Oil level adjusting range mm 115 to 123 lt lt Outside of damper comp United States model Japanese model European model Oil amount cm LH 357 RH 155 lt Oil level adjusting range cm 342 to 381 130 to 500 lt 2 Shock absorber 2 1 Spring settings United States model Japanese model European model Spring rate N mm Initial setting mm 129 8 131 3 Spring free length mm 257 5 Initial adjusting range mm 125 8 to 133 8 2 2 Damping force adjustment United States model Japanese model European model 10 click return total 22 12 click return total 22 Rebound tension damping click damping force JE click damping force adjustment adjustment 2 turns out and 4 turns in 1 turns out and 4 turns in Hi apara total ae total c l gn Sp
21. 2011 KX Technical Data 11 KX250YBF Main Specifications 1 New Technology Information 2 Main Specifications 3 Specification Sheet 4 Detailed Specifications Engine 5 Detailed Specifications Frame 6 Suspension Explanatory Material July 2010 Kawasaki Motors Corporation Japan H E Kawasaki Any reproduction copying or redistribution of this publication is prohibited without our prior permission Table of Contents KX250YBF 1 f New Technology Information A AAA T 2 Main Specifications O 3 Specification Sheet ee E E E EE 4 Detailed Specifications Engine Ignition OA A as Cylinder head EA AS Cylinder head COVA nn n Piston cylinder Pe A A AAA e Air cleaner AS A AAA AAA Kick Starter cr rra Gear LLanSMISSION rr Gear shift drum shift fopk stsrrrrrsrrrrsssessnnennnnnnnnnnnunnnnnunnnnunnnnnunnnunuunnnnunnnnnnnnnnnnun Gear shift mechanism tr rrrrrrrrssersssnsnssnnnnnnnnnnnnnunnnnnunnnnnunnnnnunnnnnunnunnunnnnnnnnnnnne Crankcase ER aeaa a RR RAR ERRE a AROS RS AR EN EA Engine ee 2 ace eee a alae il Wetter coe Fuel PUMP lal aca a ae i Ln ea Fuel Injection TTC CCR CR TORRE CETTE CTE CE PELLET ROT ERT CCE CURE TE PUTER TILER T TTC a ree OIl UO see seebee arena a antic a a a SE sates Water atian ae ie eee eee ee ane nc einstein PS RBadiator er eee ecco Generator RA aa A O RADICA a e RR a E a a TTR Or Tre 5 Detailed Specifications Frame Frame fittings RA AN ERA A
22. 328 92153 f N B 11055C 11056 RA Ref Generator Ref Ignition System 11055 11056A a Ref Frame 132 11055A 132 A4A Ref Rear Suspension Modifications from 10 KX250XAF to 11 KX250YBF O 5 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Bracket ACG connector 11055 1840 Newly specified due to employment ot Fi system ol Bracket vehicle down sens mossas 0O C To BracketIgcol mosom lt o oO OoOo o To Damper gco o2161 0878 i o Coler geo f 9249 1057 i o Not 19 eo ezo ss i To Bot gc IES i BECERA Bott bracket mounting 132BA0610 tol P 92019 1328 92153 11055C 11056 Ref Generator Ref Ignition System 11055 110564 Ref Frame 132 132 11055A 132 A4 Ref Rear Suspension Modifications from 10 KX250XAF to 11 KX250YBF o ees et O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change ith 33001 0196 33001 0245 ab overall length has been changed 6 mm compared wit lo o Guide chain 12053 0160 12053 0178 The durability has been improved 1O O Bolt M6 x 42 92154 0130 92154 0511 The surface treatment has been changed Jo O Bolt M6 x 10 2151 1233 182840810 OOOO TT Too Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10
23. 47 44013 0165 The structure has been changed SFF damper leg Ol x y O 44071 Y ly 44008 921548 O 32085 E O E a0026 A 8 S O G Q 440718 Va 2 N D S O S oO 46102A 44013A 44013 430589 lf Modifications from 10 KX250XAF to 11 KX250YBF O 5 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Damper assembly RH____ 44071 0647 44071 00747 The structure has been changed SFF spring leg JPN JOf x Bolt adjust bolt comp 92154 0410 The initial adjuster has been added FOL _x lt Rod joint rod comp 46102 0153 The structure has been changed SFF spring leg LOL x Ring centering plate 44008 0047 44008 0016 The degree of rigidity has been changed LOL TL Pipe fork outer 44008 0047 44008 0016 The degree of rigidity has been changed FOL TL Pipe fork inner RH_____ 44013 0148 44013 0164 The structure has been changed SFF damper leg JOf x Bolt center boltcomp____ 92184 0409 The structure has been changed SFF damperleg JO 0000000 O rat 43058 _9 Modifications from 10 KX250XAF to 11 KX250YBF O S 11 10 interchangeable as a O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement a Inter Part name 10 part 11 part Modification
24. Bore and stroke mm 1753 6 Compression ratio 13 2 Starting system Primary kick Ignition system Digital AC CDI system Digital DC CDI system Lubrication system semi dry sump Carburetor Keihin s FCR37 Throttle body Keihin s 43 mm dia Transmission type Constant mesh 5 speed return lt Clutch type Wet multi disc 1st 2 142 2nd 1 769 3rd 1 444 4th 1 200 5th 1 045 E 6th Primary reduction ratio 3 350 67 20 Final reduction ratio 3 692 48 13 3 769 49 13 Frame type Semi double cradle aluminum Telescopic fork Showa s inverted inner tube Suspension 47 mm dia Swingarm New unified traction suspension 315 310 80 100 21 51M 100 90 19 57M Single disc 250 mm dia Single disc 240 mm dia Engine type Gear ratios Wheel travel Tire size Ty Tt TITI TITTI Brake type Fuel capacity liters 8 0 N N 4 Detalled Specifications Engine O S 11 gt 10 interchangeable as a Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance ee ee blo COIL IGNITION 21121 0021 21121 0058 A from the plughole type to the external CAP ASSY PLUG N 21160 0009 Changed due to redesigned ignition coil x PLUG SPARK 92070 0019 92070 0020 CR8E CPRB8E projecting electrode ty
25. E A RA eT ER ARA AER ERA O RA AAA Swingarm TEP COCR a a a a a a a aa Rear suspension REL ET O a a O RRA a REO E e tre a FOOt Tester Front master cylinder AAA Front brake a Rear master cylinder AAA Rear brake o ELLE LEE Decals A A E A A A Accessories A E T Suspension Specifications Standard rere ee eer TCR ee a A er re eee ee er ree Optional Parts A A A eee ee eT a Identifying the KX250Y suspension springs A 6 Suspension Explanatory Material 11M KX250Y Functions of Suspension System AS Features of Suspension System A Basic Structure of Suspension System a Adjustment of Suspension System ns Inspection and Maintenance of Suspension System rerrrrtrrrrmermeenennnnsnnenennass Notes about Overhauling the Suspension System a 2 Suspension Setting cen RRR A Modification of KX250Y 2011 Year Model Suspension System vssesee Information about KX250Y 2011 Year Model Suspension System w7 Front Fork Ol Flow Moqdel ssssssssss s uusuunnnunnunnunununnunuunuunununnunuunnnunnununnnunnn LASEK PII 1 New Technology Information 2011 KX250F LAS PILI O Piston e The piston head has been redesigned to improve engine performance at 2010 model 2011 model high speed and overrun areas e The side hole of piston pin is not used 2010 model 2011 model Changed er O Cylinder e The cylinder height has been changed Modification 1 and the piston head has been reshaped therefore the co
26. E Read the Service Manual and follow the relevant procedure during overhauling E When disassembling the suspension system exercise care not to damage the sliding surface of the slide pipe and the rod surface with your tools WE Use the specified special tools only MW Left side lf you have removed the damper and adjusting bolt component right side and if you fully extend the slide pipe and the outer tube the guide bushing and the slide bushing may contact each other and be damaged Exercise care not to damage them except when replacing the bushings NW Left side When you tighten the damper rod and the bottom center bolt fully mount the locknut on the rod by hand Then tighten the center bolt the whole way in After that tighten the locknut E Right side When you tighten the rod of the joint rod component and the upper adjusting bolt component fully mount the locknut on the rod by hand Then tighten the adjusting bolt component the whole way in After that tighten the locknut E Mount the snap ring of the oil seal correctly into the groove WE Tighten all parts with the correct torque specified in the Service Manual gt If you tighten the under bracket excessively the suspension system may experience an operation error However if the tightening torque is insufficient the front forks may shift and this could lead to a dangerous accident w Center bolt FJ IN N SHOWA Ea E Do not change the mounting height of t
27. Modification 3 Reduced inertial moment for 4 kg cm 2010 model im Modification 2 2010 model 2011 model AS D O JN ex pe Web dimensions 23 5 mm 21 mm CA SF e The balancing ratio is the same as that for KX250XAF 60 O Exhaust pipe e The length of the exhaust pipe has been changed Modification 1 to improve engine performance at low speeds Modification 1 2010 model 2011 model Web dimensions 480 mm 510 mm O Silencer Modification 1 e Four induction ports have been added to the punching pipe Modification 1 to make the exhaust gas toward the glass wool 2010 model 2011 model Insulator 36 1 mm dia Modification 1 O Air cleaner duct e The duct and funnel capacity has been increased by 10 to improve engine response at low speeds 2010 model 2011 model LEK PILI Transmission e The transmission gear ratio has been changed to improve engine Modification 1 performance Modification 2 Modification 1 2010 model 2011 model 2nd gear 1 769 1 750 Modification 2 2010 model 2011 model Ath gear 1 200 1 235 O Gear change mechanism e The ratchet rotation angle has been changed Modification 1 to ensure smooth gear change ee Modification 1 Due to this change the ratchet size Modification 2 gear change shaft design Modification 3 and the return spring tension have been modified
28. NTROL UNIT 21175 0320 The ECU has been added US and CN ELECTRONIC specifications DAMPER 2161 0842 Used to mount the ECU O SENSOR 1176 0009 The water temperature sensor has been added O SENSOR 1176 0066 The vehicle down sensor has been added O O O SENSOR 1176 0121 The intake air temperature sensor has been added BOLT 2154 0038 Used to mount the intake air temperature sensor 11055 Ref Hand1ebar IS OPTION Ref Handlebar Ref Frame Fittings OPTION 211768 EFI O S 11 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement AO A aah i aaam Modific change O CONTROL UNIT 21175 0322 The ECU has been added US EU and AU ELECTRONIC specifications DAMPER 2161 0842 Used to mount the ECU O SENSOR 1176 0009 The water temperature sensor has been added O SENSOR 1176 0066 The vehicle down sensor has been added O O O SENSOR 1176 0121 The intake air temperature sensor has been added BOLT 2154 0038 Used to mount the intake air temperature sensor 11055 Ref Hand1ebar IS OPTI
29. ON Ref Handlebar Ref Frame Fittings OPTION 211768 EFI O S 11 gt 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF 0 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement E are AA Modific E Inter O x CONTROL UNIT ELECTRONIC 21175 0349 The ECU has been added BR specifications DAMPER O SENSOR O SENSOR O SENSOR O BOLT O 11055 Ref Hand1ebar IS OPTION Ref Handlebar Ref Frame Fittings OPTION 211768 Oil pump O S 11 10 interchangeable as a Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement it oe Inter f Part name 10 part 11 part Modifications change Not modified Ref Crankcase Water pump O S 11 gt 10 intercha
30. RING i 00000 O Gear change mechanism O S 11 10 interchangeable as a ot Modifications from 10 KX250XAF to 11 KX250YBF 0 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance pee anaE RATCHET 13078 0019 13078 0029 The lever length has been changed OS LEVER COMP Modified to increase rotation angle in conjunction CHANGE SHAFT 19161 0067 13161 0027 ith ratchet Os SPRING 92145 0609 92145 0775 The set load has been reduced O P g Qos Ref Gear Change Drum Shift Fork s Ref crankcase Q SS gt S T V 921458 O Crankcase O S 11 10 interchangeable as a D Modifications from 10 KX250XAF to 11 KX250YBF 0O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement 10 part 11 part Modifications afell The switch comp mount in the left case has SET CRANKCASE 14001 0164 14001 0155 been changed a LH Side Cover engine
31. able 3 Others KX250Y 2 Reliability improvement 1 Performance improvement 10 part 11 part Modifications change STEEL OPTION STEEL OPTION Modifications from 10 KX250XAF to 11 KX250YBF o ees et O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement a Inter Not modified Modifications from 10 KX250XAF to 11 KX250YBF O S 11 10 interchangeable as a ul O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement ld saa 11 part Modifications change 92057 0191 92057 0192 From 112LINK to 114LINK o Os Sprocket 42041 1448 42041 1450 From AL48T to AL50T JPN US CN AU O OS 42041 F G y A2041A7E OPTION oS OPTION ALUMINIUM N STEEL Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a e O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement epee 11 part Modifications change 92057 0191 92057 0192 From 112LINK to 114LINK ol Os Sprocket 42041 1448 42041 1449 From AL48T to AL49T EU BR O OS 42041 F G6 A2041A7E OPTION ALUMINIUM OPTION STEEL Modifications from 10 KX250XAF to 11 KX250YBF Se gt TO Miarchangeabis asa eh O 11 gt 10 interchangeable 3 Others KX250Y 2 Re
32. arate BCV Setting Table e The oil lock is too tight e Reduce the clearance of oil lock valve e Change the tapered angle and length of the bottom holder e The compression damping force is too large and the e Increase the stroke by reducing the compression damping force head is springy T 1 The head shakes on the braking gap e Springy due to the high reaction force e Reduce the amount of oil to release the spring force e Increase the stroke by reducing the main spring rate e Insufficient tension TEN damping force e Improve the controllability by increasing the tension TEN damping force Cloudy and unstable e Insufficient compression COMP damping force e Improve the controllability by increasing the compression COMP damping force e The main spring is too soft e Increase the reaction force by increasing the main spring rate e The compression COMP damping force is too large e Reduce the damping force for the COMP Hi speed a Q Kick up occurs during braking e Insufficient tension TEN damping force e Increase the damping force for the TEN Hi speed e The RC sinks due to the engine power and the fork e Increase the damping force for the COMP Lo speed strokes are too long The damping force must not increase for MID Hi speed e The main spring rate 1s too high and there 1s e Reduce the main spring rate to increase the initial force insufficient initial force e The tension TEN damping
33. e for the COMP Lo MID speed 7 Suspension System Setting SHOWA Settings for jumping FF e The suspension strokes e Insufficient damping force against G force e Increase the damping force for the COMP MID Hi speed excessively when the motorcycle is jump started Insufficient compression COMP damping force or grounded e Insufficient reaction force e Increase the amount of oil e Increase the main spring rate FF e The suspension bottom e Insufficient oil lock load e Increase the oil lock load out occurs when grounded after jump FF e Suspension feels hard e The oil lock load is too high e Reduce the oil lock load after a jump FF e The front forks raise when e Insufficient tension TEN damping force e Increase the damping force for the TEN MID speed the motorcycle is jump started e The suspension strokes e Insufficient damping force against G force e Increase the damping force for the COMP MID Hi speed excessively when jumping Insufficient compression COMP damping e Raise the C A valve or riding on the ground force e Reduce the restrictor continuous hole diameter e Insufficient reaction force e Increase the main spring rate e Rear kick up occurs when e Insufficient tension TEN damping force e Increase the damping force for the TEN MID speed the motorcycle is jump started e The compression COMP damping force is too e Reduce the damping force for the COMP MID speed
34. e regulator Control pressure See the Service Manual measurement 2 Air tightness Appearance and Visual There must be no cracks damage Replace the Connector ee air tightness Inspection or fuel leakages assembly e Appearance and Visual There must be no cracks damage Plastic fuel pipe joint A l T air tightness inspection or fuel leakages Plastic resin housing Appearance and Visual There must be no cracks damage y Holder air tightness inspection or fuel leakages Visual There must be no cracks damage Appearance 1 Inspection or fuel leakages Aluminum body Visual There must be no cracks dents or O ring seat T inspection fuel leakages FPM Checkpoints 2 3 Appearance Wire hamesaleads EEEN Visual There must be no cable Replace the PP inspection damage exposure or disconnection assembly Inspection For the standard FPM replacement procedure see the Service Manual 9 Detalled Specifications Frame Modifications from 10 KX250XAF to 11 KX250YBF Se gt TO Miarchangeabis asa en O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement a Inter Frame comp main 32160 0417 32160 0404 The bracket has been added due to employment of Fl system JO x Ref Front Fork Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a a O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement
35. eds fuel Calculates the sensor information by the CPU and determines These are carried out by the mechanical system the fuel rate Injects the fuel via the injector at the determined rate Fuel SAN injector LIZA Throttle Y Fuel injection aD da command 3 Fuel gt Throttle Throttle position sensor opening n ntake air pressure sensor Engine speed Crankshaft sensor KX250F DFI System Outline The DFI system consists of the ECU Fuel Pump Module FPM throttle body and various sensors such as crankshaft sensor water temperature sensor intake temperature sensor and vehicle down sensor that have been designed specifically for motocrossers Throttle body Ba Fuel injector 4 Throttle position sensor sensor Various sensors ap Crankshaft sensor Water temperature sensor Built in CDI igniter Intake air temperature sensor By Vehicle down sensor Ignition coll Gear position sensor Features of Motocrosser DFI System The DFI system is designed specifically for motocrossers contributing to the greatly enhanced power output It features high throttle response increased startup performance highly stable fuel delivery and Y compact size and light weight Primary components Advantages Starting control without battery power Reduced startup time Weights approximately 200 g 10 less than the KLX250 s ECU Throttle body
36. er riding we recommend that you wash the motorcycle and inspect the following points Scratches of slide pipe Oil leakage Looseness of tightened parts MW Replacing the oil in the front forks The front fork strokes and absorbs shock while riding At the same time a bending load is applied to the front forks in various directions and its bushings or other components will gradually wear away In addition when the travel distance increases the oil viscosity and other characteristics will change and the damping force on the front forks may reduce In such a case replace the oil In general replace the oil of the front forks three or four times a year every three or four races gt When replacing the oil we recommend that you replace the consumable parts such as slide bushings guide bushings oil seals and dust seals NM The drain bolt is mounted on the fork bolt area This bolt releases the internal pressure of the front forks to that of atmospheric pressure We recommend that you remove the drain bolt and release the internal pressure of the front fork to the atmospheric pressure before riding 5 Inspection and Maintenance of Suspension System SHOWA 2 Rear suspension The rear shock absorber is not only a simple damper that affects riding quality and shock absorption it also has the important function of holding the rear wheel of the motorcycle through the frame link as described above Routinely check and maintain the front
37. fications from 10 KX250XAF to 11 KX250YBF O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance ee ere Inter 10 part 11 part Modifications Hehe 11061 0354 11061 0434 The part number has been changed for better control Changed due to modifications made to exhaust A aise regulations US and CN specifications PIPE EXHAUST 18088 0524 18088 0565 The length has been changed Changed due to modifications made to exhaust BODY ASSY MUFFLER 18100 0111 18100 0110 regulations US and CN specifications Changed due to modifications made to exhaust noise regulations US and CN specifications CLAMP 92173 0174 92173 0275 The surface treatment has been changed PIPE COMP 31064 0185 31064 0211 11061A 92173 18100 Ref Frame Muffler Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance ee eee 10 part 11 part Modifications 2 o sande 11061 0354 11061 0434 The part number has been changed for better control 18046 0177 18046 0231 Changed due to modifications made to exhaust noise regulations JPN AU EU and BR specifications 18046 0224 The heat insulating wool f
38. force is too high and e Increase gap traceability by reducing the tension TEN damping force packed a Q Not smooth on the gap during acceleration Too hard a Q T Cloudy and unstable e Insufficient tension TEN damping force e Improve the controllability by increasing the tension TEN damping force e Insufficient compression COMP damping force e Improve the controllability by increasing the compression COMP damping force e The main spring is too soft e Increase the reaction force by increasing the main spring rate 7 Suspension System Setting SHOWA Settings for cornering FF e The motorcycle dives e Insufficient reaction force and the MC easily e Raise the main spring rate to create a sensation of progression when approaching a dives e Increase the reaction force by increasing the amount of oil corner e The damping force is insufficient and the MC is e Increase the compression COMP damping force to improve the MC stability e Set the BCV see the separate BCV Setting Table e It is difficult to trace the e The tension TEN damping force is too high e Reduce the damping force for the TEN Lo MID speed cornering line due to the and gap traceability is poor unstable FF oor traction a push out or others e The compression COMP damping force is too e Reduce the damping force for the COMP Lo MID speed occur high and gap traceability is poor e The BCV is too ha
39. forks to assure safety by following the important instructions given below E Oil leakage from the sealing When the motorcycle is brand new oil may leak However this is oil that was added during the assembly process You can wipe it a few times and the oil leaks will stop WE Check to see that the slider section such as the rod is free of dents and rust If a seal is damaged it may lead to an oil leakage After riding always check to see that the slider section is free of dents E All nuts and bolts must be tight at the rear shock absorber mounting area lf any fasteners are loose the rideability may be significantly reduced and in the worst scenario the motorcycle may roll over E After riding we recommend that you wash the motorcycle and inspect the following points Scratches on rod surface Oil leakage Looseness of tightening parts WE Handling of the rear shock absorber The rear shock absorber is filled with high pressure nitrogen gas Never disassemble the rear shock absorber and never expose it to an open flame or fire 3 Other notes 6 Overhauling of Suspension System 1 Front forks Ml Before disassembling the front forks always remove mud and dust by washing the motorcycle MW Left side Before beginning disassembly check the current setting position of the damping force adjuster E Left side When disassembling the suspension system set the damping force adjuster to the loosest adjustment position
40. ges significantly when you jump in foe example motocross riding the fuel pump is protected with a rubber fuel filter cover in order to ensure stable supply of fuel Note 1 This cover closes the fuel inlet port and functions as a fuel trap In addition the fuel return hose which is connected between the pressure regulator and the fuel filter cover always keeps fuel in this fuel trap The capacity of the fuel tank has been changed from 8 liters to 7 5 liters e Generator The inertia moment has been changed Modification 1 2010 model 2011 model Modifi _ Modification 1 2010 model 2011 model Ca cation 2 IN O AMO j Inertia moment eS Approx t eS 4 4 kg cm 9 0 kg cm The output characteristics remain unchanged Modification 2 2010 model 2011 model ACG rotor 76 mm dia 100 7 mm dia e Ignition system The static coil has been changed to the ignition coil to improve engine characteristics 2010 model e Spark plug SED The spark plug has been changed to close the electrode to the center of combustion chamber for improvement of combustion performance Modification 1 2010 model 2011 model Modification 1 Spark plug CR8E CPR8EB 9 Modification 2 2010 model 2011 model Extent of fork Sse ian Modifi bounce 1 cation 2 Distance from the top end of the electrode to the cylinder head surface e Troubleshooting Fl indicator light opt
41. he front forks at the left and right sides Tighten the mounting bolts E Adjusting bolt component 6 Overhauling of Suspension System SHOWA 2 Rear suspension WE Before disassembling the front forks always remove mud and dust by washing the motorcycle WE Before beginning disassembly check the current setting position of the damping force adjuster E When disassembling the suspension system set the damping force adjuster to the loosest adjustment position WE Before removing the spring measure the spring length and place the markings on the locknut and the spring adjuster These markings will be very useful during reassembly WE Before disassembling the rear shock absorber make sure that the high pressure gas contained inside has been removed WE Wash and clean the end plate to remove any remaining mud E During reassembly mount the snap ring in the groove correctly gt If the snap ring is not mounted correctly a problem may occur while riding In the worst case oil may leak out and riding may become very dangerous Make sure that the snap ring is correctly mounted in the groove Spring adjuster ret a E T End plate ST Oe o
42. ility improvement 1 Performance improvement ee Inter Seat assembly 53066 0244 53066 0279 The side leather pattern has been changed OL O Bolt M8 92153 1308 132BA0816 The surface treatment has been changed Jo O Ret Side Covers Modifications from 10 KX250XAF to 11 KX250YBF O 5 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Cable clutch 54011 0087 54011 0096 The inner cable length has been changed 8 mm BE Cable throttle 54012 0265 54012 0286 The overall length has been changed and the protector has been added Cable starter 54017 0014 ET LO ae O Ret Radiator Ref Radiator Modifications from 10 KX250XAF to 11 KX250YBF Se gt TO Miarchangeabis asa en O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement pets 11 part Modifications change Bolt M6 92153 0863 92150 1506 The surface treatment has been changed Ret Seat O S 11 10 interchangeable as a set O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change 26031 0755 26031 0912 Modified due to employment of FI system fol x cramp JO eorna Ade To Modifications from 10 KX250XAF to 11 KX250YBF Ref Frame Modifications from 10 KX250XAF to 11 KX25
43. inder Outside of damper comp Oil amount adjusting range ml 848084 to 381 Damper oil amount inside of damper comp ml 260 a velan SIONES Damper oil level Standard oll amount of optional spring K 9 5 N mm mi Oil amount adjusting range at right side ml 130 to 492 Standard oil amount of optional spring K 8 7 N mm mi Oil amount adjusting range at right side ml 130 508 Recommended oil brand Showa s SS 19 9 Information about 2011 Model Suspension System SHOWA 2 Rear suspension Japanese model European model Same as the US model Rebound Adjusting range Total number of clicks 22 5 tension damping Standard number of adjuster clicks MAX 10 MAX 12 MAX 10 High speed Adjuster adjusting range rotations Total number of clicks 4 0 5 compression damping Standard adjuster clicks rotations MAX 2 MAX 1 MAX 2 Low speed Adjusting range Total number of clicks 19 6 compression damping Standard number of adjuster clicks MAX 8 Standard spring mount length mm 257 5 Standard setting position mm Dimension A 129 8 131 3 129 8 Mounting length adjusting range mm 255 263 United States model Dimension A a Set position adjusting range mm Dimension A 125 8 to 133 8 Mounting length adjusting range mm Optional spring K 53 9 N mm 252 to 263 Set position adjusting range mm Dimension A 125 8 to 136 8 Mounting length adjusting range mm Optional spring K 53 N mm 249 3
44. interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Bolt shock absorber 92153 1386 92154 0513 The surface treatment has been changed fol x Bolt shock lower 92153 0937 92154 0512 T fol x Bolt tie rod 92154 0106 92154 0394 T fol x 92154B Ref Swingarm Q Ref Shock Absorber s Cs 3 Y Y Y y fi A Ref Frame Modifications from 10 KX250XAF to 11 KX250YBF O S 11 10 interchangeable as a aa O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement pee 11 part Modifications DERE change Bolt M8 92153 0838 92154 0515 Spring LH 92145 0198 92145 0800 Spring RH 92145 0199 92145 0801 The treatment has been changed JO x Ref Frame Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a ul O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement Not modified F Ny Ref Frame Modifications from 10 KX250XAF to 11 KX250YBF O 5 11 gt 10 interchangeable as a oot O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement ME Inter Not modified Modifications from 10 KX250XAF to 11 KX250YBF o ees et O 11 10 interchange
45. ion force is too large and the stroke is large e Reduce the main spring rate to increase the initial force e Cloudy and too many e Insufficient tension TEN damping force strokes while rising e Increase the damping force for the TEN MID speed e Insufficient compression COMP damping force e Increase the damping force for the COMP Lo MID speed 7 Suspension System Setting SHOWA Settings for down hill riding FF e The motorcycle dives e Insufficient compression COMP damping e Increase the entire compression COMP damping force when braking while riding force down hill e Insufficient reaction force e Increase the amount of oil e Insufficient BCV e Set the BCV see the separate BCV Setting Table e The spring is hard when e The oil lock load is too large e Reduce the oil lock load deeply stroked on a down hill e The suspension is hard e The compression COMP damping force is too e Reduce the damping force for the COMP MID Hi speed and springy on a down large hill gap e The reaction force 1s too large e Reduce the amount of oil e Reduce the main spring rate e Rear wheel kick up occurs e The compression COMP damping force is too e Reduce the damping force for the COMP MID Hi speed when riding down hill large e Insufficient tension TEN damping force e Increase the entire tension TEN damping force e Poor C A damping force control e Reduce the inner diameter of the C A re
46. ional part No 23016 0049 If the DFI system or ignition system part fails the indicator lights up to warn the rider Mount the Fl indicator light on the handle holder using the bracket part No 11055 1673 Note 1 Then remove the empty connector optional and connect the signal cable LEK PILI lt Cabling ECU FI indicator light Connector for troubleshooting EH 6 pin Optional connector GM A a a Mounting el Connector position Connector for Optional connector troubleshooting ECU o 2 Troubleshooting using the Fl indicator light optional Remove the capacitor connector connect the power wiring harness part No 26011 0246 and connect it to the battery 12 V Then ground the GND cable of the FI indicator light The system enters the DEALER mode and you can troubleshoot by checking the flashing of the FI indicator light CC Cabling Capacitor connector H Connect gt Mode indication Flashing Ground For details refer to the Service Manual 8 Troubleshooting using the KDS3 Remove the capacitor connector connect the power wiring harness part No 26011 0246 and connect it to the battery 12 V KDS3 connection Cabling x Capacitor connector imi H Connect J Connector for troubleshootin g E 6 pin Op
47. large e The reaction force 1s too large e Reduce the main spring rate e The tension TEN damping force is too large e Reduce the damping force for the TEN MID speed e The rear height is insufficient when the motorcycle is jump started e Insufficient compression COMP damping force e Increase the damping force for the COMP MID speed O Q Q e Insufficient reaction force e Increase the main spring rate 7 Suspension System Setting SHOWA Settings for up hill riding Possible causes Solutions e The front tire has poor e The compression COMP damping force is too e Reduce the damping force for the COMP Lo speed griping ability large e Reduce the damping force for the TEN Lo speed e The tension TEN damping force is too large e The rear height is e Insufficient compression COMP damping insufficient when started force to rise e Increase the damping force for the COMP Lo speed e Insufficient reaction force e Increase the initial force of the main spring e Increase the main spring rate e Traction is insufficient on e Insufficient compression COMP damping the rising gap force e Increase the damping force for the COMP MID speed e The tension TEN damping force 1s too large e Reduce the damping force for the TEN MID speed e The operation is not e The tension TEN damping force is too large smooth on the rising gap e Reduce the damping force for the TEN MID speed e The react
48. le 3 Others O S 11 10 interchangeable as a set KX250Y 2 Reliability improvement 1 Performance improvement l i fee te Inter PUMP FUEL O Newly added due to employment of Fl system JPN eee US CN AU and EU specifications O Used to mount the fuel pump O O lt y Ref Fuel Tank Fuel pump O S 11 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others EN 2 Reliability improvement 1 Performance dela Aa Inter PUMP FUEL 49040 0037 Newly added due to employment of Fl system Newly added due to employment of Fl system BR specifications 670E5070 Used to mount the fuel pump 92154 0534 Used to mount the fuel pump e TUBE ASSY 51044 0098 Ref Fuel Tank EFI O S 11 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement AO A aah i aaam Modific change O CO
49. liability improvement 1 Performance improvement A gs Inter Bolt M10 92153 0974 92154 0516 The surface treatment has been changed Jo O Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a l O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement a Inter Part name 10 part 11 part Modifications change Shock absorber 45014 0303 45014 0309 The valve specifications and comp ADJ alumite color have been changed JPN Rod ssid 46102 0145 46102 0159 The valve specifications have been changed JPN OL O 461024 00U 03 0 lt gt e CCC CCL amp OPTION Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a e O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement Part name 10 part 11 part Modifications change The valve specifications and comp ADJ alumite color have been Shock absorber 45014 0280 45014 0309 changed US CN AU of o Rod ssid 46102 0145 46102 0159 The valve specifications have been changed US CN AU OL O 461024 00U 03 0 lt gt e CCC CCL amp OPTION Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a e O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improve
50. light XN A For details refer to the Service Manual contained in the package LEK PIII O Front fork SFF Separate Function front Fork e The SFF is first used on the MX series machines e The damper and spring functions are divided into left and right sides The low friction parts to allow smooth operation and stable damping characteristics 2 Light weight 3 The preload adjuster has been added to allow wider settings e After the following four modifications were carried out the imbalance of left and right characteristics has been eliminated and the impressive handling performance has been achieved The taper of the outer tube has been redesigned and the torsional rigidity has been improved 2 The spring was mounted in reverse on the front brake caliper and the difference between left and right mass has been reduced 8 A joint rod has been added to the inside of the right front fork and the rigidity of the left and right forks has been equalized The joint rod also functions to restrict the fork to stretching fully and moving to the center of the spring 4 The left front fork has a restrictor to limit the oil flow through the outer cylinder and the damping force increases when the suspension stroke increases Additional damping force is dynamically added in the intermediate stroke range of the left front fork A 2010 model 2011 model A Left and right sides Lef
51. ment 1 Performance improvement as Inter Part name 10 part 11 part Modifications change Shock absorber 45014 0304 45014 0330 The valve specifications and comp ADJ alumite color have been changed EU BR Rod ssid 46102 0152 46102 0159 The valve specifications have been changed EU BR OL O 461024 00U 03 0 lt gt e CCC CCL amp OPTION Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement i er Inter Cylinder master 43015 0155 43015 0167 The body anticorrosion treatment has been changed fol O 43015 QU Modifications from 10 KX250XAF to 11 KX250YBF O S 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement Part name 41080 0090 41080 0192 Reshaped outer shape Disc optional 41080 0082 41080 0193 1 OPTION Modifications from 10 KX250XAF to 11 KX250YBF O S 11 10 interchangeable as a set O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change Cylinder assembly master 43015 0142 43015 0168 The cap anticorrosion treatment has been changed oi lol o Cap brake 43026 0008 43026 0023 1
52. mpression ratio has been changed Modification 2 Modification 1 2010 model 2011 model Height 36 5 mm 36 3 mm ya Modification 2 2010 model 2011 model Compression ratio 13 271 15 331 O Valve system parts e The extent of lifting Modification 1 and the profile and valve timing Modification 1 Modification 2 of the intake camshaft have been modified Modification 1 2010 model 2011 model Extent of lifting 8 7 mm 9 3 mm Intake valve timing Modification 2 2010 model 2011 model BTDC 41 degrees 40 degrees ABDC 71 degrees 72 degrees e Due to the change of the extent of lifting of the camshaft the load of the intake valve spring Modification 3 has been modified Modification 2 Modification 3 Modification 1 2010 model 2011 model O Cylinder head e The wall thickness of the cylinder head bolt shown at right was increased by 1 5 mm Modification 1 to improve reliability Modification 1 2010 model 2011 model Wall thickness 3 0 mm 4 5 mm LEK PILI O Crankshaft e Due to the change of flywheel the diameter of the crankshaft has been increased Modification 1 Modification 1 Modification 1 2010 model 2011 model O Shaft diameter 18 mm 21 mm t gt R Modification 2 Modification 3 Modification 2 e Also the crankshaft web has been redesigned
53. n contrast to the front forks the bladder chamber is filled with high pressure nitrogen gas Damper ad EE a 47 T m Bladder High pressure gas chamber 4 Adjustment of Suspension System 1 SHOWA WE in order to check the balance between the front and rear parts of the frame you need to check the sag E When the rider is seated the rider s weight can be set to 1G This is an important step to take to fully utilize the performance of the motorcycle Note The sag 1G of rider is the amount that the height of the motorcycle decreases when the rider is seated More precisely the sag is the difference between the two distances the distance from any reference position on the spring to the axle shaft when the suspension is fully extended and the distance from any reference position on the spring to the axle shaft when the rider is seated The adjustment process may be easy if any reference position on the spring is set at the bottom of front under bracket and at an intersection between the rear side plate and the rear fender F Measured value A Measured value B Sag M The sag 1G of rider is generally one third of the full stroke of the suspension system E Although it varies depending on the taste of each rider the appropriate value is in the following ranges M You can adjust the sag 1G of rider using the s
54. nd link arm Throttle position sensor Features Progressive Link The new Progressive Link structure optimizes the intake airflow rate The throttle operation is flexible when the valve opening is small and the throttle quickly responds when the valve opening Is intermediate approximate 3 8 Progressive link system Improved throttle response RS FCR MX37 Degree of flexibility similar to that of the FCR system Airflow rate increases gt Throttle opening increases gt Adjustment Functions Idling speed adjustment and cold starter The throttle body has a bypass air tunnel separate from its main bore It has Airflow rate adjustment function at idling speed and Y Cold starter function Airflow rate adjustment at Cold starter idling speed Rotate the control CCW Idling speed adjustment amp choke knob Idling speed adjustment amp Airflow rate Ss choke knob Increases Engine speed increases Rotate the control CW Airflow rate decreases Engine speed Pull out the control toward you decreases It functions as the starter when the engine is cold Engine speed increases Notes on Handling Throttle Body The throttle body system Is a precision electronic part Be sure to handle it with care when carrying out maintenance Before removing or installing the throttle body remove dust mud and other substances from around the th
55. ngeable as a Modifications from 10 KX250XAF to 11 KX250YBF 11 110 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change as es Not modified Ref Engine Cover s Radiator O S 11 gt 10 interchangeable as a Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement ae Bat Modifications change A capacitor mounting nut has been installed on the RADIATOR ASSY LH 39061 0179 39061 0190 tomes eine 92153 0503 92150 1435 The surface treatment has been changed 8 bolts 92153 0864 92150 1801 The surface treatment has been changed 2 bolts 92150 92150 92150 ref Cables Ref Cables TVEN water Pump A As Generator O S 11 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others e EN 2 Reliability improvement 1 Performance ee eae Inter STATOR 21003 0091 21003 0102 New ACG for the Fl system without battery power
56. nting bolt M10 x 35 mm M10 x 32 mm 2 Main Specifications 3 Specification Sheet Main Specification Change of 11 KX250YBF Modified engine hanger Material from Al to Fe Thickness from t8 0 to 14 5 Modified due to employment of Fl system Seat Redesigned fuel tank Redesigned side leather Redesigned electronic components addition of new sensors Shock absorber o Pronk fork Changed valve specifications _ SFF structure used Changed fork offset from 23 5 to 22 5 Redesigned swing arm Reviewed overall length Changed the engine bracket material Material from Al to Fe Thickness from t6 0 to t4 5 Engine 1 Fl system without battery power employed 2 Transmission gears Improved riding performance achieved by changing 2nd and 4th reduction ratio 3 Piston Performance improved due to reshaped top surface 4 Camshaft Performance improved due to changed cam profile 5 Change mechanism Enhanced assuredness in shifting due to changed ratchet etc Exhaust pipe Change in length employment of SUS taper type exhaust pipe Specification Sheet EU BR A 10 KX250XAF 11 KX250YBF Overall length mm 2170 Overall width mm 820 Overall height mm 1270 Wheelbase mm 1470 Road clearance mm 340 Seat height mm 955 Caster angle degrees 27 7 Trail mm 122 3 Single cylinder 4 stroke liquid cooled DOHC 4 valve engine Displacement cm 249
57. or the outside has been added JPN AU EU and BR specifications PIPE EXHAUST 18088 0524 18088 0565 The length has been changed BODY ASSY MUFFLER 18100 0110 18100 0114 Changed due to modifications made to exhaust noise regulations JPN AU EU and BR specifications PIPE COMP 31064 0195 31064 0195 Changed due to modifications made to exhaust noise regulations JPN AU EU and BR specifications CLAMP 92173 0174 92173 0275 18088 11061A The surface treatment has been changed 92173 Ref Frame 18100 Modifications from 10 KX250XAF to 11 KX250YBF O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement Valve O S 11 gt 10 interchangeable as a dl change SPRING VALVE 49078 0056 49078 0080 The spring constant has been increased EE OL OS A ES 490T7BA Camshaft tensioner O S 11 gt 10 interchangeable as a set 3 Others Engine KX250Y 2 Reliability improvement 1 Performance improvement i i Haie i Inter Part name 10 part 11 part Modifications 112 CAMSHAFT COMP The cam profile and the valve timing have been dll Crankshaft O S 11 1
58. pe spark plug x Ref Frame Ref Frame Fittings J S2070 A Head cylinder O S 11 10 interchangeable as a ae Modifications from 1 0 KX250XAF to 11 KX250YBF O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement AEEA Inter M f Part name 10 part 11 part odifications change 11008 0191 11008 0218 HEAD COMP CYLINDER HOLDER CARBURETOR 16065 0056 16065 0074 CLAMP 92171 0925 92171 0857 The water jacket has been partly reshaped to support installation of water sensor Redesigned due to modification from cab to throttle a body Redesigned due to modification from cab to throttle S body NS Head cover cylinder O S 11 10 interchangeable as a Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others Engine KX250Y 2 Reliability improvement 1 Performance del anaE E modified Piston cylinder O S 11 gt 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3
59. pring preload adjuster of the suspension Adjuster position gt OF Appropriate value Front forks 45 to 55 mm absorber Top end of right front fork Circumference of rear shock cylinder 4 Adjustment of Suspension System SHOWA 2 Adju sti ng the d amping force M Make sure that the damping force adjuster is in the normal status before riding M Set the damping force adjuster in the desired position by referring to the separate Setup Manual Caution Do not force the adjuster notch when rotating it gt When fully tightened the number of clicks may change due to the tightening force Always set the adjuster using the same tightening force Compression gt Front fork Left side Compression side Top surface Damping adjuster Front fork Left side Pulling side Bottom surface Damping adjuster Axle holder Rear shock absorber Right surface Compression side Top surface Damping adjuster Punch mark at the Punch mark at the chassis side chassis side Rear shock absorber Right surface Pulling side Bottom side Damping adjuster Lower metal O Punch mark at the high Punch mark at the low a E speed adjuster side speed adjuster side 5 Inspection and Maintenance of Suspension System Oil leakage from the sealing When the motorcycle is brand new some oil may leak out However this is oil that was added during
60. rate Spring length a 6 07 to 11 N mm Standard Optional Standard Optional mm AAA AO y O gt gt Oo O SO gt O o gt y O gt gt Oo 265 E ee ee gt ee 1 6 KX250YBF Suspension Explanatory Material Suspension Explanatory Material 11M Kx250Y Showa Corporation Motorcycle Suspension Development Dept 1 Functions of Suspension System SHOWA The suspension system such as front forks and rear shock absorber of a motorcycle has the following important functions 1 Holds tl he frame of the motorcycle 2 Keeps the front and rear wheels in position 3 Absorbs mechanical shock Functions 1 and 2 are used for enhancement of frame rigidity and for control of the motorcycle position when the suspension system is linked to the motorcycle framework Function 3 absorbs mechanical shock from the road and helps the rider maintain control and stability Rear shock absorber 2 Features of Suspension System SHOWA The suspension system the front forks and rear shock absorber consists of the following two system elements 1 Spring system and 2 Damper system The spring system W Holds the frame in the appropriate position and absorbs mechanical shock W Increases the load reaction according to the spring stroke and prevents the bottom from being hit WE The front forks have an air chamber and when thi
61. rd e Set the BCV see the separate BCV Setting Table FF e Cloudy and poor traction Too large movement e Insufficient tension TEN damping force e Increase the damping force for the TEN Lo MID speed e Insufficient compression COMP damping force e Increase the damping force for the COMP Lo MID speed e The BCV is too soft e Set the BCV see the separate BCV Setting Table FF e Handling is heavy e The tension TEN damping force is too high e Reduce the entire tension TEN damping force and handling feels heavy RC e It is difficult to trace the e Reduce the damping force for the TEN Lo MID speed cornering line due to the poor traction e The tension TEN damping force is too high and gap traceability is poor e The compression COMP damping force 1s too high and gap traceability is poor e Keep the damping force for the COMP Lo speed but reduce the damping force for the MID Hi speed RC e The gripping force of the e The damping force is insufficient for COMP Lo rear wheel is insufficient speed during acceleration and traction is poor e Increase the damping force for the COMP Lo speed The damping force must not increase for MID Hi speed RC e Cloudy and poor traction e Insufficient tension TEN damping force Too large movement e Increase the damping force for the TEN Lo MID speed e Insufficient compression COMP damping force e Increase the damping forc
62. rottle body to prevent them from entering the throttle valve throttle link lever fuel pipe joint and intake air pressure sensor of the fuel injector Do not drop or subject the throttle body to impact In particular if the throttle lever or link lever is deformed or damaged the throttle valve may fail to return smoothly In the worst case It may result in an accident Because the fuel injector intake air pressure sensor and throttle position sensor are high precision parts handle them with care Do not assemble modify or process the throttle valve link lever throttle stopper or other parts except when specified to do so by the Service Manual Use only genuine parts by following the instructions in the Service Manual when you replace parts Throttle Body Checkpoints 1 1 Throttle and starter system Checkpoint Method Requirements Corrective actions m Check its The throttle operation must be Replace the Operability operation smooth assembly Visual There must be no deformation or Appearance 1 Inspection damage Visual There must be no deformation or Appearance il inspection damage Visual There must be no deformation or Appearance 1 Inspection damage Visual There must be no deformation or Appearance 7 T inspection damage Visual There must be no deformation or l Appearance Replace it inspection damage Operability Check its The throttle operation must be A operation smooth Parts Throt
63. s air is compressed a reaction force is generated and the progressive spring characteristics can be obtained WE The rear shock absorber provides progressive bounce characteristics according to the frame link characteristics Note When the spring is loaded it temporarily absorbs the energy of this input load When the load is removed the spring radiates the absorbed and stored energy that is the spring elongates lf a spring is used alone vibration of the frame is not absorbed due to free vibration or other reasons and frame Stability will reduce The energy to increase the spring length is controlled by the damper system The damper system E Controls the spring length Damping operation WE Uses the damping force pushing process to absorb additional mechanical shock that cannot be absorbed by the spring system alone gt Mechanical shock is absorbed and the rider and motorcycle frame are protected from damage E Changes the damping force generated by the damper according to the speed of the motorcycle E Converts most of the energy absorbed by the damper into heat energy and releases it into the air The damper is heated 3 Basic Structure of Suspension System SHOWA 1 Front forks WE Each front fork consists of a spring a chamber and an air damper M This model features a SFF Separate Function front Fork structure consisting of separated spring and dampers M This damper in particular has separate pressure cons
64. s pE EFA change The structure has been changed Damper assembly RH 44071 0648 44071 0696 SFF spring leg US CN AU CANNES Bot adustbot comp 92164 0410 The nial adjuster has been added TOA Rod joint rod comp 46102 0163 The structure has been changed SFF springe OL Ring centering plate 44008 0047 44008 0016 The degree of rigidity has been changed TO SY Pipe ford outer 44008 0047 44008 0016 The degree of rigidity has been changed TO Pipe for inner RH 44013 0148 44073 0164 The structure has been changed SFF damperieg O Bolt center boltoomp 92464 0400 The structure has been changed SFF damperleg fol O 44071 y Y ly 44008 92154B Cc 32085 Sj aao267478 D S O S oO 46102A 44013A 44013 430589 wolf 0000000 O ul a 2 N Modifications from 10 KX250XAF to 11 KX250YBF O 5 11 gt 10 interchangeable as a set O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement change The structure has been changed SFF spring leg EU BR OL gt x Bolt adjust bolt comp____ 92154 0410 The initial adjuster has been added JO x Rod joint rod comp 46102 0153 The structure has been changed SFF spring leg JO x Ring centering plate 44008 0047 44008 0016 The degree of rigidity has been changed JO x Pipe fork outer 44008
65. t side Right side F Damper chamber Damper chamber gt Joint rod Air oil separate system Air oil separate system 2 component Air chamber Air chamber O he Restrictor de ld D eS Spring ba O O Oil level Oil level Ine Q Spring I ies O 8 Brake caliper mounting position 2011 model Spring 2 Joint rod 3 Preload adjuster Damping force adjuster when extended Restrictor Damper chamber Air oil separate system Damping force adjuster when compressed LEK PILI e Front fork offset Modification 1 The front fork offset has been changed in order to improve the feeling of lightness cornering performance and front traction performance Modification 1 2010 model 2011 model Offset amount 23 5 mm 22 5 mm e Coating To improve operation characteristics the operating surfaces of both the inner tube and outer tube were coated Titanium coating O Rear shock absorber e The valve setting has been changed to improve damping absorption Also the inner wall of the cylinder is finished by Kashima Coating Kashima Coating inish inner surface O Swingarm e The thickness of the drive chain guide has been changed KX450F parts are commonly used on the 2011 model and later y Modification 1 Modification 1 2010 model 2011 model Modification 2 Thickness 7 2 mm 12 3 mm 2010 model Modification 2 2010 model 2011 model
66. tartup performance is even higher than that of a vehicle with a carburetor Engine stop button A capacitor has been added to stabilize voltage Self Diagnostic Functions The DFI system has a Troubleshooting mode as a self diagnostic function If the DFI system has failed the Fl alarm indicator flashes and the failure location is identified in the Troubleshooting mode a special tool is required for this Notes on motorcycle inspection When you inspect the motorcycle connect a battery and the Fl alarm indicator to the motorcycle and check that the Fl alarm indicator does not light up Also repeat kicking of the engine more than 10 times and check again that the alarm indicator does not light up These kicks allow the system to detect a fuel injector or ignition system failure For details see the Service Manual Failure Fl alarm indication pattern in Fl alarm indication in MAA IO oma Dg tr JM _ Inter pressure sensor A a a rod AA Water temperature sensor a Fm Crankshaft sensor as O AUL n Gear position sensor a Vehiele down sensor AAA Fuel injector OO o SU Fue pump o U AA nition coit Sensor amp Device Failure and ride at a minimum rate even If the DFI system has failed Failure location Stn dig Crankshaft sensor impossible Stp Vehicle down sensor Impossible Stop Fuel injector Impossible Stop Fuelpump Impossible Stp Ignition coil Impossible S
67. the shaft has been changed BOLT 92154 0181 92154 0521 The surface treatment has been changed dll 92154 Cover s SPid5A Gear transmission O S 11 gt 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 gt 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement The number of gear teeth has been changed from OS 13T to 16T GEAR INPUT 2ND The number of gear teeth has been changed from OUT 13262 0673 13262 0841 23T to 28T OS GEAR INPUT 2ND IN 13262 0775 13262 0839 The number of gear teeth has been changed from OS 20T to 17T The number of gear teeth has been changed from OS 24T to 21T GEAR INPUT 4TH IN 13262 0777 13262 0840 GEAR INPUT 4TH OUT 13268682E 13262 0675 13262 0842 13268682H COPT ION gt Gear change drum and shift fork O S 11 gt 10 interchangeable as a set Modifications from 10 KX250XAF to 11 KX250YBF O 11 10 interchangeable 3 Others KX250Y 2 Reliability improvement 1 Performance improvement Mean eas Modifications AA change 4 DRUM CHANGE 13141 0052 13141 0054 Gear speed detection is supported O Changed from the neutral detection to the gear SWITCH COMP 13151 0006 13151 0052 speed detection SCREW PIN RING O GASKET SP
68. tic resin housing Holder Pressure regulator Fuel Rubber cover A Fuel filter Fuel return hose Fuel pipe joint Aluminum body Connector Notes on Handling FPM The Fuel Pump Module FPM is an important fuel delivery system component Be sure to handle it with care when carrying out maintenance Before removing or installing the throttle body remove dust mud and other substances from around the throttle body to prevent them from entering the throttle valve throttle link lever fuel pipe joint and intake air pressure sensor of the fuel injector Do not disassemble the components such as power terminals plastic housing pressure regulator fuel pipe joint and connectors Do not drop or subject the FPM to impact When you have removed the fuel tank do not let the fuel pipe joint come in contact with the ground When you have removed the fuel hose care not to let any foreign substances enter the fuel pipe Do not carry the FPM by holding its wire harness When you have removed the FPM from the fuel tank do not leave it as it Is Ensure that no electricity is flowing when the fuel tank is empty Replace the FPM by following the relevant procedure in the Service Manual FPM Checkpoints 1 1 Performance and functions Discharging AAGE See the Service Manual AEP ACE MG rate assembly Fuel pump Cable Continuity The signal circuit must be y disconnection check conductive Pressur
69. tional connector Troubleshoot the DFI using the KDS3 LEK PILI LS KX Racing Software Optional e Outline KX Racing Software can set the ECU data and save and analyze the engine operation data on a personal computer PC e Main functions Data setting function By connecting the PC to the ECU of motorcycle you can change the amount of fuel injected and ignition timing settings of the engine Also this software contains sample data of the KX450F 2010 year model and the KX250F and KX450F 201 1 year models that can be used for setup reference 2 Data recording function The engine speed throttle opening and various other trip data can be recorded in the ECU controller The recorded data can be displayed and analyzed on a PC using a simple analysis graph The recording items are the recording start and end trigger types sampling rate recording mode and others For detailed information please refer to the Kawasaki Racing Kit Manual that will be released at a later date e Connection to the motorcycle The ECU controller terminal is now mounted at the rear of the front number plate on both the KX250F and KX450F 2011 year models although it was mounted under the gasoline tank on the KX450F 2010 year model Mounting the ECU controller Be sure to mount the ECU controller by using the brackets and sub harnesses contained in the controller package Connect to the FI indicator
70. tle system Throttle valve Throttle lever Link arm Link lever Throttle cover ldling speed adjustment and choke knob Throttle Body Checkpoints 2 2 Fuel system ARPeSranes Visual There must be no cracks damage Fuel rail and air Replace it Inspection or fuel leakages tightness 3 Sensors Voltage oe See the Service Manual Replace it Intake air pressure sensor Visual There must be no cracks or Appearance fi inspection damage Rubber pipe of intake air Visual There must be no cracks damage Appearance oressure sensor inspection or disconnected components Voltage Apu See the Service Manual voltage Visual There must be no cracks damage Connector 7 inspection or disconnected components Throttle position sensor Visual There must be no cable Harness inspection damage exposure or disconnection There must be no cracks or Appearance inspection damage Resistance Aeae See the Service Manual between pins He Moci n ligero Visual There must be no cracks damage x inspection or fuel leakages tightness For the standard parts replacement and adjustment procedure see the Service Manual Features of Motocrosser DFI System Fuel Pump Module FPM Fuel Pump Module FPM Specifications Dedicated design of motocrossers Optimized layout of rubber cover and fuel return hose to allow constant fuel delivery Weight reduced by using plastic resin housing and aluminum body Plas
71. to 236 Set position adjusting range mm Dimension A 125 8 to 139 5 Mounting length adjusting range mm Optional spring K 52 N mm 253 5 to 263 Set position adjusting range mm Dimension A 125 8 to 135 3 Mounting length adjusting range mm Optional spring K 50 N mm 254 9 to 263 Set position adjusting range mm Dimension A 125 8 to 133 9 Dimension A Mounting length adjusting range mm Optional spring K 49 N mm 253 to 263 nent This is a reference distance between the center of upper needle bearing and the Set position adjusting range mm Dimension A 125 8 to 136 2 spring upper surface Set position adjusting range mm Dimension A 125 8 to 135 8 Mounting length adjusting range mm Optional spring K 48 1 N mm 252 6 to 263 Mounting length adjusting range mm Optional spring K 47 N mm 249 5 to 263 Set position adjusting range mm Dimension A 125 8 to 139 3 9 Information about 2011 Model Suspension System SHOWA 3 Optional springs 11M Standard parts ESA 11M Optional parts Optional springs of front fork Spring constant KAWASAKI parts Identification Remarks K 9 1Nimm 44026 0152 11M Standard Optional springs of rear shock absorber Spring constant KAWASAKI parts Identification Remarks K 47 N mm 92145 0464 Silver painted SOFT K 48 1 N mm 92145 0411 Black painted SOFT K 50 N mm 92145 0346 White painted SOFT
72. top For rider s safe and engine protection engine start is impossible and engine is stopped while running if crankshaft sensor vehicle down sensor fuel injector fuel pump and ignition coil failure detected Notes on Handling ECU The Electronic Control Unit ECU is a precision electronic part Be sure to handle it with care when carrying out maintenance Because the ECU Is a precision part do not drop or subject it to impact Do not touch the ECU terminals The electronic circuits may be damaged by the static charge Remove water dust mud and other substances from around the ECU connector before removing or installing the ECU When installing the ECU fully insert it into the slot until the ECU connector locks Otherwise the ECU operation may fail Do not splash water under high pressure on the ECU connector for a long period of time Otherwise the ECU may fail to start or the ECU electronic parts may be damaged Features of Motocrosser DFI System Throttle Body KX250F Throttle Body Specifications Dedicated design of motocrossers Throttle control Uses the progressive link system Throttle bore 43 mm diameter Reduced weight Approximately 600 g of throttle body half of the carburetor system Intake air pressure sensor Throttle control Fuel injector Fuel rail Idling speed adjustment amp choke knob MESES IFRI FT fi Throttle cover Throttle valve Link lever a
73. truction that is rigid enough to withstand the large impacts involved in motocross riding or other demanding types of use Note As the SFF structure has the spring at a single side only it can reduce the sliding friction and improve the riding quality Note The separate pressure construction dampers of the front forks have been developed not only to maintain the constant damping force but also to prevent the damping force from falling due to the mixture of oil and air inside the air chamber HI Conventional A Left SFF 3167 SEP A EJE leal Preload Integrated adjuster common to left and right sides front fork damper EEE ma ea mame same a Integrated spring O Q Joint rod component cE EHE EE E E E EEE EEE EEE A e e E A A A A P I N 4 Ss a P a is i a a A A i E a as 3 Basic Structure of Suspension System SHOWA 2 Rear suspension M The rear suspension system consists of the swingarm and linkage mechanism of the frame and the rear shock absorber M The rear shock absorber consists of the spring and damper E For the damper of this model the air chamber which is completely separate from the hydraulic oil system is mounted in the reservoir tank to maintain a stable damping force Note The air chamber is completely separate from the oil due to the bladder I
74. turn ring The oil returns too fast e Reduce the restrictor continuous hole diameter e The compression COMP damping force is too e Reduce the damping force for the COMP MID Hi speed large e The tension TEN damping force 1s too large e Reduce the entire tension TEN damping force e Poor C A damping force control e Increase the inner diameter of the C A return ring The oil returns too slowly e Increase the restrictor continuous hole diameter FF FF RC RC e The suspension is hard and springy on a down hill gap 8 Modifications of 2011 Model Suspension System SHOWA 1 Front forks Adoption of IS ka Separate Function front Fork Features Single side damper and spring mounting realizes reduced friction between parts and improved riding quality Added positional dependency by restrictor arrangement Integrated damper plus increased cylinder diameter from 23 mm to 28 mm dia Left fork lt Ri h i f k Added joint rod component gt No DF lt gt Rebound support Long spring At Ig or centering Reduced stiffness difference between left and right forks GA pa va gt 0 0600000 00 00 POCLISL 0066000660000 ecre i n A ee ee ae eee

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