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Kawasaki KLX 250 old service manual

1. Oil Pump Installation Notes Clean any metal particles and dirt off the oil screen A Fill the oil pump with engine oil for initial lubrication Check to see that the knock pins B O ring C screen and new gasket are in place Oil Pump Disassembly Remove the oil pump Remove the circlip B and pull out the oil pump gear shaft Remove the oil pump cover screws E and then take off the pump cover A Take out the inner rotor and outer rotor C Washer D Pump Gear http mototh com 6 8 ENGINE LUBRICATION SYSTEM Oil Pump Assembly Notes Apply a non permanent locking agent to the threads of the oil pump cover screws Before installing the oil pump be sure the shaft and rotors turn freely Oil Pump Drive Gear Removal The oil pump drive gear is removed during primary gear removal see Engine Right Side Left Side chapter Oil Pump Drive Gear Installation The oil pump drive gear is installed during primary gear installation see Engine Right Side Left Side chapter Oil Pressure Measurement Measuring the oil pressure when the engine is cold about room temperature is a way to inspect relief valve operation First inspect the relief valve operation when the engine is warmed up to measure the oil pressure at the normal operating temperature When the engine is cold Remove the oil filter cap from the engine and install the oil pressure gauge cap using the original bolts
2. Wet the cap sealing surfaces with water or coolant to prevent pressure leaks http mototh com Install the cap A on a cooling system pressure tester Bj Watching the pressure gauge pump the tester to build up the test pressure The cap must open at the specified relief pressure the gauge hand flicks down O Also the cap must hold the relief pressure for at least 6 seconds l f the cap cannot hold the pressure or the relief pressure is too high or too low replace the cap with a new one Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kg cm2 14 18 psi Filler Neck Inspection Check the radiator filler neck for signs of damage Check the condition of the top A and bottom B sealing seats in the filler neck They must be smooth and clean for the radiator cap to function properly Water Hose Breather Hose Air Vent Hose Inspection In accordance with the Periodic Maintenance Chart visually inspect the hoses for signs of deterioration Squeeze the hose A hose should not be hard and brittle nor should it be soft or swollen Replace any damaged hose Water Hoses Breather Hose Air Vent Hose Installation Notes Install the water hoses A breather hose B or air vent hose C being careful to follow the performed bends see Exploded View Cable Wire and Hose Routing in the General Information chapter Avoid sharp bending kinking flattening or twisting Tighten the hose clamps secure
3. Detach the strip of caps from the container NOTE O Do not discard the strip of caps because it is used as the battery plugs later O Do not peel back or pierce the sealed areas 1 Strip of Caps 2 Sealed Areas 3 Container Place the electrolyte container upside down with the six sealed areas in line with the six battery filler ports Push the container down strongly enough to break the seals Now the electrolyte should start to flow into the battery NOTE ODo not tilt the container as the electrolyte flow may be interrupted Make sure air bubbles are coming up from all six filler ports O Leave the container this way for 5 minutes or longer http mototh com SUPPLEMENT FOR 1994 MODEL 17 9 NOTE Off no air bubbles are coming up from a filler port tap the bottom of the bottle two or three times Never remove the container from the battery CAUTION Fill until the container is completely emptied 1 Air Bubble Be certain that all the electrolyte has flowed out Tap the bottom the same way as above if there is any electrolyte left in the container Now pull the container gently out of the battery Let the battery sit for 20 minutes During this time the electrolyte permeates the special separators and the gas generated by chemical reaction is released Fit the strip of caps tightly into the filler ports until the strip is at the same level as the top of the battery NOT
4. Remove the caps on the bottom of the outer tubes Hold the front fork in a vise Stop the cylinder from turning by using the fork cylinder holder handle A and adapter B Unscrew the cylinder valve assembly C and take the cylinder valve assembly and gasket out of the bottom of the outer tube Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1057 Hexagon Wrench Hex 29 57001 1335 Remove the cylinder unit D from the top of the front fork tube http mototh com 12 8 SUSPENSION Separate the inner tube from the outer tube as follows O Remove the retaining ring A from the outer tube B O Mount the front fork outer tube weight on the top of the outer tube by fitting the step of the weight to the top corner of the outer tube Special Tool Fork Outer Tube Weight 57001 1218 O Holding the inner tube by hand in a vertical position stroke the outer tube up and down several times and pull it down This shock to the fork leg separates the outer tube from the inner tube A Inner Tube B Outer Tube Seal C Oil Seal D Washer E Outer Tube Guide Bushing F Inner Tube Guide Bushing Remove the cylinder base A from the bottom of the outer tube B http mototh com SUSPENSION 12 9 Front Fork Assembly Notes Assembly is the reverse of disassembly Check the O ring at the top plug Replace it with a new one if damaged Replace t
5. Remove the right engine cover Pull out the oil screen A Installation Note Clean the oil screen thoroughly whenever it is removed for any reason Cleaning and Inspection Clean the oil screen with a high flash point solvent and remove any particles stuck to it AWARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE O While cleaning the screen check for any metal particles that might indicate internal engine damage Check the screen carefully for any damage holes and broken wires l f the screen is damaged replace it http mototh com 6 12 ENGINE LUBRICATION SYSTEM Oil Pipe Main Oil Pipe Installation Notes Before installation flush out the pipe with a high flash point solvent Fill the pipe with engine oil to shorten air bleeding time and prevent engine damage Discard the used gaskets and install new gaskets on each side of the pipe fittings Lightly tighten the banjo bolts and mounting bolt to a snug fit and tighten the banjo bolts Torque Banjo Bolt 012 20N m 2 0 kg m 14 5 ft lb A Banjo Bolts 010 9 8 N m 1 0 kg m 7 0 ft lb B Main Oil Pipe Removal Remove Clutch Cable Lower End Remove the banjo Bolts A and take off the pipe B If the banjo bolt is removed while th
6. 25 44 20 25 Hand Tighten about 3 9 2 5 4 5 2 0 2 5 Hand Tighten about 0 4 18 0 33 14 5 18 0 Hand Tighten about 35 in lb S Electrical System Spark Plug Magneto Flywheel Bolt Stator Coil Mounting Bolts Pickup Coil Mounting Screws 14 120 5 9 2 5 1 4 12 0 6 0 25 10 87 52 in lb 22 in lb The table below relating tightening torque to General Fasteners thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads TTThhhrrreeeaaadddsss dddiiiaaa m mmm mm Torque N m kg m ft lb 5 6 8 10 12 14 16 18 20 3 4 4 9 5 9 7 8 14 19 25 34 4 4 61 73 98 1 1 5 1 5 5 165 225 225 325 0 35 0 50 0 60 0 80 1 4 1 9 2 6 3 5 4 5 6 2 7 4 10 0 11 5 16 0 17 0 23 0 23 33 30 43 in lb 52 69 in lb 10 0 13 5 19 0 25 0 33 4 5 5 4 72 83 115 125 165 165 240 http mototh com GENERAL INFORMATION 1 17 Special Tools and Sealant Piston Ring Pliers 57001 115 Bearing Puller 57001 135 Bearing Puller Adapter 57001 136 Steering Stem Bearing Driver 57001 137 Inside Circlip Pliers 57001 143 Outside Circlip Pliers 57001 144 Oil Pressure Gauge 10 kg cm2 57001 164 Fork Cylinder Holder Handle 57001 183 Compression Gauge 57001 221 Valve Spring
7. Brake fluid change Brake master cylinder cup and dust seal replace Brake caliper piston seal and dust seal replace Brake hose replace Spoke tightness and rim runout check Drive chain adjust Drive chain lubricate Drive chain wear check Chain slipper and guide replace Front fork inspect clean Front fork oil change Steering play check http mototh com 6 Replace add adjust clean or torque if necessary R Replace Service more frequently when operated in a race US U S model Steering stem bearing grease Rear sprocket check Wheel bearing lubricate Swingarm and uni trak linkage pivots grease Swingarm and uni trak linkage pivots check Rear shock oil change ENGINE and CHASSIS Fuel system clean Fuel hose replace Nuts bolts fasteners tighten General lubrication perform http mototh com 7 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasekt Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads LG Apply liquid gasket to the threads SS Apply silicone sealant to the threads S Tighten the fasteners following the specified sequence FFFaaasssttteeennneeerrr Torque RRReeem m maaarrrkkksss N m kg m ft lb Cooling System
8. Check to see that the crankcase knock pins are in place on the left crankcase half If any of them has been removed replace it with a new one A p p l y liquid gasket to the mating surface of the left crankcase half Sealant Kawasaki Bond Liquid Gasket Silver 92104 002 Using a suitable tool on the right crankcase to press around the hole for the crankshaft fit the crankcase halves together with a press on the tool NOTE O Constantly check the alignment of the two crankcase halves and the position of the transmission shafts and shift drum The front and rear of the crankcase must be pushed together evenly http mototh com CRANKSHAFT TRANSMISSION 8 7 Remove the crankshaft jig from the flywheels Tighten the crankcase bolts starting with the ones around the crankshaft and then the farther ones Torque Crankcase Bolts 9 8 N m 1 0 kg m 87 in lb Check to see that the crankshaft and output shaft all turn freely in the neutral position l f the crankshaft will not turn probably the crankshaft is not centered tap the appropriate end of the crankshaft with a mallet to reposition it Spinning the output shaft shift the transmission through all the gears to make certain there is no binding and that all the gears shift properly Install the parts removed in the reverse order of removal and refer to the appropriate chapters O Replace the O ring on the output shaft with a new one
9. KLX250E http mototh com FINAL DRIVE 10 3 Specifications Item Standard Service Limit Drive Chain Standard Chain KLX250D Make DAIDO Type D I D 520DS 6 Link 110 links KLX250E Make ENUMA Type EK520LV O Link 106 links Chain slack 55 65 mm Too tight less than 55 mm Too loose more than 70 mm 20 link length 317 5 318 2 mm 323 mm Sprockets Engine sprockf t diameter KLX250D 6 0 6 9 6 1 19 mm 14T 60 3 mm KLX250E 60 98 61 18 mm 14T 60 3 mm Rear sprocket diameter KLX250D 237 54 238 04 mm 49T 237 2 mm KLX250E 202 32 202 82 mm 42T 202 0 mm Rear sprocket warp 0 4 mm or less 0 5 mm Special Tools Inside Circlip Pliers 57001 143 Bearing Driver Set 57001 1129 Jack 57001 1238 http mototh com 10 4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection Stand the motorcycle with its side stand Check the wheel alignment see Wheel Alignment Inspection and adjust it if necessary see Wheel Alignment Adjustment NOTE O Clean the drive chain if it is dirty and lubricate it if it appears dry Rotate the rear wheel to find the position where the chain is tightest Measure the space A between the chain and the swingarm at the rear of the slipper as shown l f the drive chain slack exceeds the standard adjust it Drive Chain Slack Standard 55 65 mm Drive Chain Slack Adjustment KLX250D Remove the cotter pin A and loose
10. Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser Continued on next page http mototh com NOTE o The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are exceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c Ad
11. Water Pump Impeller Nut 7 8 0 8 69 in lb Coolant Drain Plug 25 2 5 18 0 Thermostat Housing Cap Bolts 9 8 1 0 87 in lb Elbow Water Pipe Mounting Bolts 9 8 1 0 87 in lb Thermostatic Fan Switch 8 8 0 90 78 in lb Water Temperature Sensor 8 8 0 90 78 in lb Engine Top End Cylinder Head Cover Bolts 7 8 0 8 69 in lb Camshaft Cap Bolts 12 1 2 8 5 S Camshaft Sprocket Bolts 12 1 2 8 5 L Cylinder Head Bolts 6 mm 9 8 1 0 87 in lb S Cylinder Head Allen Bolts first torquing 15 1 5 11 0 S standard torquing 46 4 7 34 s Camshaft Chain Guide Mounting Bolt 25 2 5 18 0 Camshaft Chain Guide Bracket Bolt 9 8 1 0 87 in lb Carburetor Holder Mounting Bolt 12 1 2 8 5 Camshaft Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Camshaft Chain Sub Tensioner Bolt 15 1 5 11 0 Inspection Cap 2 5 0 25 22 in lb Rotor Cap 2 5 0 25 22 in lb Engine Right Side Left Side Engine Oil Drain Plug 15 1 5 11 0 Clutch Hub Nut 78 8 0 58 L Clutch Spring Bolts 3 2 0 33 29 in lb Shift Drum Cam Allen Bolt 12 1 2 8 5 L Return Spring Pin 29 3 0 22 0 L Primary Gear Nut 98 10 0 72 Magneto Flywheel Bolt 12 mm 120 12 0 87 L 10 mm 88 9 0 65 Kick Ratchet Guide Bolt 9 8 1 0 87 in lb L External Shift Mechanism Cover Bolts and Nut 9 8 1 0 87 in lb External Shift Mechanism Cover Screw 5 4 0 55 48 in lb Position Lever Nut 9 8 1 0
12. change Steering play check Steering stem bearing grease Continued on next page http mototh com GENERAL INFORMATION 1 11 FFFRRREEEQQQUUUEEENNNCCCYYY OOOPPPEEERRRAAATTTIIIOOONNN Traveled Distance km mi 100 60 500 300 1000 600 1500 900 2000 1200 Rear sprocket check Wheel bearing check Swingarm and uni trak linkage pivots grease Swingarm and uni trak linkage pivots check Rear shock oil change Every year ENGINE and CHASSIS Fuel system clean Fuel hose replace Every 4 years Nuts bolts fasteners check General lubrication perform Replace add adjust clean or torque if necessary R Replace Service more frequently when operated in a race US U S model http mototh com 1 12 GENERAL I N F O R M A T I O N Periodic Maintenance Chart KLX250E The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected Spark plug clean and gap Valve clearance check Air cleaner element clean Air cleaner element replace Throttle grip play check Idle speed check Fuel system check Evaporative emis
13. http mototh com 8 8 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod Removal Split the crankcase see Crankcase Splitting Remove the transmission shafts see Transmission Shaft Removal Remove the balancer see Balancer Removal Using a press remove the crankshaft from the left crankcase If the bearings stay on the crankshaft when splitting the crankcase or removing the crankshaft from the left crankcase remove the bearings from the crankshaft with a bearing puller Special Tools Bearing Puller 57001 135 A Bearing Puller Adapter 57001 136 B Installation Notes When installing the crankshaft bearings apply high temperature grease to the outer sides of the bearings and then press them into the crankcase using the bearing driver set until the bearing bottoms against the step Special Tool Bearing Driver Set 57001 1129 A Insert the crankshaft jig between the crankshaft flywheels opposite the connecting rod big end to protect flywheel alignment as shown and press the crankshaft into the left crankcase OWhen pressing position the jig in the crankcase opening so the jig does not hit the crankcase Special Tool Crankshaft Jig 57001 1174 A Apply engine oil to the connecting rod big end bearing Connecting Rod Big End Side Clearance Measure the side clearance B of the connecting rod with a thickness gauge A l f the clearance exceeds the service limit replace
14. mototh com SUPPLEMENT FOR 1994 MODEL 17 1 Supplement 1994 Model This Supplement 1994 Model chapter is designed to be used in conjunction with the front part of this manual up to 19 2 The maintenance and repair procedures described in this chapter are only those that are unique to the 1994 KLX250G 1 motorcycle Most service operations for this model remain identical to those described in front of this chapter Model KLX250E Complete and proper servicing of the 1994 KLX250G 1 motorcycle therefore requires mechanics to read both this chapter and the text in front of this chapter Model KLX250E Table of Contents General Information 17 2 Model Identification 17 2 General Specifications 17 3 Periodic Maintenance Chart KLX250 G1 17 5 Technical Information Maintenance Free Battery 17 7 Fuel System 17 11 Specifications 17 11 Suspension 17 12 Specifications 17 12 Electrical System 17 13 Specifications 17 13 KLX250 G1 Wiring Diagram 17 15 Battery 17 17 Headlight Circuit Wiring Diagram 17 19 Turn Signal Light Circuit Wiring Diagram 17 19 Radiator Fan Circuit 17 20 Coolant Temperature Warning System 17 21 http mototh com 17 2 SUPPLEMENT FOR 1994 MODEL General Information Model Identification KLX250 G1 KLX250 G2 http mototh com SUPPLEMENT FOR 1994 MODEL 17 3 General Specifications Items KLX250 G1 G2 Dimensions Overall length 2170 mm W 2220 mm Overall width 870 mm Over
15. 3 18 COOLING SYSTEM Thermostatic Fan Switch Water Temperature Sensor KLX250E Thermostatic Fan Switch Removal Drain the coolant see Coolant Draining Disconnect the thermostatic fan switch connector A Unscrew the fan switch B and remove it CAUTION The fan switch should never be allowed to fall on a hard surface Such a shock to this part can damage it Thermostatic Fan Switch Installation Note Tighten the thermostatic fan switch Torque Thermostatic Fan Switch 8 8 N m 0 90 kg m 78 in lb Thermostatic Fan Switch Inspection Refer to the Electrical System chapter Water Temperature Sensor Removal Disconnect the water temperature sensor connector A Unscrew the sensor B and remove it CAUTION The water temperature sensor should never be allowed to fall on a hard surface Such a shock to this part can damage it Water Temperature Sensor Installation Notes Apply silicone sealant Kawasaki Bond 56019 120 to the threads before installing the water temperature sensor Tighten the water temperature sensor Torque Water Temperature Sensor 8 8 N m 0 90 kg m 78 in lb Water Temperature Sensor Inspection Refer to the Electrical System chapter http mototh com ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded View 4 2 Specifications 4 4 Cylinder Head Cover 4 7 Removal 4 7 Installation Notes 4 7 Camshaft Chain Tensioner 4 8 Removal 4 8
16. 57001 1072 Rim Protector 57001 1063 Bearing Driver Set 57001 1129 Jack 57001 1238 Bearing Remover Shaft 57001 1265 Bearing Remover Head 015 x 017 57001 1267 Bearing Remover Head 20 x 022 57001 1293 http mototh com 9 4 WHEELS TIRES Wheels Rims Front Wheel Removal Using the jack under the frame stabilize the motorcycle Special Tool Jack 57001 1238 A Remove Speedometer Cable Lower End A Cotter Pin B Loosen the axle nut C Remove the axle nut pull out the axle and remove the wheel CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Insert a wood wedge between the disc brake pads this prevents them from being moved out of their proper position should the brake lever be squeezed accidentally Front Wheel Installation Notes Install the collar A on the left side of the hub Install the speedometer gear housing A so that it fits in the speedometer gear drive notches B Fit the speedometer gear housing stop A to the fork leg stop B Torque the axle nut Torque Front Axle Nut 88 N m 9 0 kg m 65 ft lb Install a new cotter pin Check the front brake AWARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake w
17. 9 8 N m 1 0 kg m 87 in lb Fill the cooling system with coolant see Coolant Filling in the Cooling System chapter Fill the transmission with oil see Engine Oil Change in the Engine Lubrication System chapter Adjust Clutch Cable Rear Brake http mototh com 5 8 ENGINE RIGHT SIDE LEFT SIDE Clutch Removal Remove the clutch cover see Clutch Cover Removal Remove the magneto flywheel cover Install the flywheel holder A on the magneto flywheel NOTE O Use the flywheel holder to prevent the clutch from rotating Special Tool Flywheel Holder 57001 1313 A Remove the spacer B if provided clutch pusher A and spring plate pusher C in the spring plate D Remove the clutch hub nut A Remove the clutch assembly sleeve A and thrust washer B Separate the clutch wheel assembly and clutch housing from the clutch assembly Unscrew the clutch spring bolts A and remove the spring plate B spring C clutch hub D friction plates and steel plates from the clutch wheel Take out the jada spring and thrust washer from the clutch housing http mototh com ENGINE RIGHT SIDE LEFT SIDE 5 9 Clutch Installation Notes Installation is the reverse of removal Apply engine oil to the inside of the clutch housing gear and kickstarter driven gear Install the friction plates and steel plates starting with a friction plate and alternating
18. II III ii i i AC Lighting System KLX250E Alternator type Lighting coil resistance Regulator resistance Capacity of headlight capacitor Three phase AC 0 4 1 1 Q x 1 Q in the text 3700 5700 uF i i i i i i i i i i i i Switch and Sensor KLX250E Rear brake light switch timing Fan switch connections Rising temperature Falling temperature Coolant temperature switch connections Rising temperature Falling temperature ON after about 10 mm pedal travel From OFF to ON 94 100 C 201 212 F From On to OFF 90 93 C 194 199 F ON Less than 0 5 O OFF More than 1 MQ From OFF to ON 107 113 C 225 236 F From ON to OFF 103 106 C 217 223 F ON Less than 0 5 Q OFF More than 1 MO I I III I I III I I III Special Tools Hand Tester 57001 983 Spark Plug Wrench Hex 18 57001 1024 Rotor Holder 57001 1184 Flywheel Puller M30 x 1 5 57001 1191 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Timing Light 57001 1241 Coil Tester 57001 1242 Flywheel Holder 57001 1313 Sealant Kawasaki Bond Silicone Sealant 56019 120 http mototh com 15 6 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and observe all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them O Do not us
19. Rocker Arm Removal 12 26 Rocker Arm Installation Notes 12 26 Uni trak Maintenance 12 27 Rocker Arm Sleeve Wear 12 27 Rocker Arm Mounting Bolt Bend 12 27 SUSPENSION 12 1 http mototh com 12 2 SUSPENSION Exploded View KLX250D E Upside Down Type G L M LG T1 T2 13 T4 T5 T6 T7 T8 T9 T10 T11 T12 Apply Grease Apply a non permanent Gasket Apply Molybdenum Disulfide Grease Apply Liquid Gasket 9 8 N m 1 0 kg m 87 in lb 13 N m 1 3 kg m 9 5 ft lb 20 N m 2 0 kg m 14 5 ft lb 23 N m 2 3 kg m 16 5 ft lb 29 N m 3 0 kg m 22 ft lb 39 N m 4 0 kg m 29 ft lb 54 N m 5 5 kg m 40 ft lb 81 N m 8 3 kg m 60 ft lb 88 N m 9 0 kg m 65 ft lb 1 5 N m 0 15 kg m 13 in lb 98 N m 10 0 kg m 72 ft lb 71 N m 7 2 kg m 52 ft lb http mototh com SUSPENSION 12 3 http mototh com 12 4 SUSPENSION Specifications Item Standard Front Fork per one unit Fork inner tube diameter 43 mm Air pressure Atmospheric pressure Non adjustable Compression damper setting 14th AS 12th click from the first click of the fully clockwise position Fork oil viscosity KAYABA 01 or SAE5W Fork oil capacity Upside down 540 4 mL completely dry Conventional 633 4 mL completely dry approx 540 mL when changing oil Fork oil level Fully compressed without fork spring below from outer tube top Upside down 97 2 mm Conventional 127 2 mm Fork spring free length Upsi
20. Spark plug cap shorted or not in good contact Spark plug incorrect CDI unit trouble Pickup coil trouble Ignition coil trouble Flywheel magneto damaged Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Air bleed pipe bleed holes clogged Air cleaner clogged poorly sealed or missing Air cleaner duct loose Starter plunger stuck open Fuel level in carburetor float bowl too high or too low Fuel tank air vent obstructed Carburetor holder loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface http mototh com APPENDIX 16 5 Compression release cam K A C R sticks open Engine stalls when moving off Other CDI unit trouble Carburetor vacuum piston doesn t slide smoothly Engine oil viscosity too high Drive train trouble Brakes dragging Over heating Clutch slipping Throttle valve does not open fully Poor Running or No Power at High Speed Firing incorrect Spark plug dirty damaged or maladjusted Spark plug cap or high tension wiring damaged Spark plug cap shorted or not in good contact Spark plug incorrect CDI unit trouble Pickup coil trouble Exciter coil shor
21. Suspension Table of Contents Exploded View 12 2 Specifications 12 4 Front Fork 12 5 Conventional Type 12 5 Air Pressure Adjustment 12 5 Compression Damping Adjustment Euro 12 5 Compression Damping Adjuster Setting 12 5 Oil Level Adjustment 12 5 Fork Oil Change 12 6 Front Fork Removal 12 7 Front Fork Installation Notes 12 7 Front Fork Disassembly 12 7 Front Fork Assembly Notes 12 9 Inner Tube Inspection 12 9 Guide Bushing Inspection 12 10 Oil Seal and Dust Seal Inspection 12 10 Spring Tension 12 10 Upside down Type 12 10 Air Pressure Adjustment 12 10 Compression Damping Adjustment 12 11 Compression Damping Adjustment Setting 12 11 Oil Level Adjustment 12 11 Removal 12 13 Installation Notes 12 13 Disassembly Oil Change 12 13 Assembly Oil Change Notes 12 15 Inner Tube Inspection 12 17 Guide Bushing Inspection 12 17 Dust Seal Inspection 12 17 Spring Tension 12 17 Rear Suspension Uni Trak 12 18 Rear Shock Absorber 12 18 Rebound Damping Adjustment KLX250D 12 18 Compression Damping Adjustment KLX250D 12 18 Spring Preload Adjustment KLX250D 12 19 Removal 12 19 Installation Notes 12 20 Spring Replacement 12 20 Disassembly Oil Change KLX250D 12 21 Assembly Notes KLX250D 12 22 Spring Tension KLX250D 12 24 Scrapping 12 25 Swingarm 12 25 Removal 12 25 Installation Notes 12 25 Tie Rod Rocker Arm 12 26 Tie Rod Removal 12 26 Tie Rod Installation Notes 12 26
22. W Swiss Model http mototh com 17 12 SUPPLEMENT FOR 1994 MODEL Suspension Specifications Item Standard Front Fork per one un t Fork inner tube diameter 43 mm Air pressure Atmospheric pressure Non adjustable Compression damper setting 14th click from the first click of the fully clockwise position Fork oil viscosity KAYABA 01 or SAE5W Fork oil capacity Conventional 633 4 m L completely dry approx 540 ml_ when changing oil Fork oil level Fully compressed without fork spring below from outer tube top Conventional 127 2 mm Fork spring free length Conventional 506 mm Service limit 496 mm Rear Shock Absorber 2nd step from the stronger position Usable range 5 steps Gas pressure 980 kPa 10 kg cm2 142 psi Non adjustable Spring free length 242 5 mm Service limit 238 mm Rocker Arm Sleeve outside diameter Small 21 987 22 000 mm Service limit 21 85 mm Big 24 987 25 000 mm Service limit 24 83 mm Bolt runout Under 0 1 mm Service limit 0 2 mm http mototh com SUPPLEMENT FOR 1994 MODEL 17 13 Electrical System Specifications Item Standard Service Limit Battery Type MF Maintenance Free Battery Capacity 12V 6 Ah Voltage 12 6 V or more Charging System Alternator type Three phase AC Charging voltage 14 15V regulator rectifier output voltage Alternator output voltage more than 34 V 4000 r min rpm Chargi
23. and check the internal resistance following the table l f the readings do not correspond to the table replace the condenser unit Special Tool Hand Tester 57001 983 Condenser Internal Resistance Unit kQ 111 Tester Lead Connection Terminal Orange Black White Orange More than 5 2 Black White Should not be inspected 3 1 Tester Lead Connection 2 Check the resistance after 2 minutes 3 Do not check the resistance because of opposite of the polarity Condenser Capacity 10000 UF 50V http mototh com ELECTRICAL SYSTEM 15 25 Radiator Fan KLX250E Radiator Fan Removal AWARNING Never touch the radiator fan until the ignition switch is turned off Touching the fan before the ignition switch is turned off could cause injury from the fan blades Remove Fan Switch Connector Radiator Fan Connector A Remove the fan motor bolts C and take off the fan motor B Fan System Circuit Inspection Remove Seat Fuel Tank see Fuel System chapter Pull off the connector from the thermostatic fan switch T u r n the ignition switch to the ON position Using an auxiliary wire A connect the thermostatic fan switch lead B to the radiator ground terminal C l f the fan rotates inspect the fan switch l f the fan does not rotate inspect the following Leads and Connectors Fan Fuse Fan Motor Fan Motor Inspection Disconnec
24. end Unbolt the clutch cover bolts and take off the clutch cover CAUTION Do not remove the clutch release shaft A unless it is absolutely necessary If removed you must replace the oil seal B with a new one and apply high temperature grease liberally to the oil seal lip Clutch Cover Installation Notes There are two knock pins A on the mating surfaces of the right engine cover and clutch cover Turn the clutch release lever toward the rear Replace clutch cover gasket with a new one Adjust the clutch cable see Clutch Adjustment Torque Clutch Cover Bolts 9 8 N m 1 0 kg m 87 in lb http mototh com ENGINE RIGHT SIDE LEFT SIDE 5 7 Right Engine Cover Removal Remove Engine Oil drain Coolant drain Kick Pedal Clutch Cable Lower End and Bracket Oil Pipe Banjo Bolt Brake Pedal and Spring Water Pump Cover turn up Impeller Turn the clutch release lever toward the rear and free the release shaft from the clutch spring plate pusher CAUTION Do not remove the clutch release shaft lor clutch cover removal Clutch release shaft removal damages the oil seal in the clutch cover necessitating oil seal replacement Remove the right engine cover bolts B and take off the cover A Install the right engine cover using the kick shaft oil seal guide A to protect the cover oil seal Special Tool Kick Shaft Oil Seal Guide 57001 267 A Torque Right Engine Cover Bolts
25. 0 kg m 72 ft lb Special Tool Flywheel Holder 57001 1313 http mototh com 5 12 ENGINE RIGHT SIDE LEFT SIDE Kickstarter Kickstarter Assembly Removal Remove Right Engine Cover Pull the end of the kick spring A outof the hole B in the crankcase Pull off the kick shaft assembly A Kickstarter Assembly Installation Notes Installation is the reverse of removal Apply a non permanent locking agent to the threads of the kick guide mounting bolt Kickstarter Assembly Disassembly I Assembly Notes T h e kickstarter assembly consists of the following parts Check the kickstarter assembly parts for damage Any damaged parts should be replaced with new ones Kickstarter Assembly 1 Circlip 2 Idle Gear 3 Spring 4 Ratchet Gear 5 Kick Gear 6 Kick Shaft 7 Kick Spring 8 Spring Guide 9 Bolts lO Kick Guide 11 Washer CAUTION When assembling the ratchet gear onto the kick shaft A align the punch mark on the retched gear B with the punch mark C on the kick shaft Apply molybdenum disulfide grease to the inside of the kick gear Replace the circlips that were removed with new ones http mototh com ENGINE RIGHT SIDE LEFT SIDE 5 13 Kickstarter Idle Gear Removal Note Remove the right engine cover and clutch housing before idle gear removal see Right Engine Cover Removal and Clutch Removal Remove the idle gear circlip and pull off the idle gear Kickstar
26. 01 or SAE5W 540 4 mIncompletely dry US CN 531 4 mL approx 460 mL US CN 450 mL when changing oil Fully compressed without fork spring below from outer tube top 97 2 mm US CN 105 2 mm 460 5 mm Service limit 451 mm 12th click US CN 10th click from the first click of the fully clockwised position 13th click US CN 12th click from the first click of the fully clockwised position Standard adjusting nut position 115 5 mm 4 55 in US CN 113 5 mm 4 47 in Nut adjusting range 106 128 mm 4 16 5 04 in 980 kPa 10 kg cm2 142 spi Non adjustable SAE5W or Bel Ray SE2 40 313 mL 255 mm Service limit 250 mm 21 987 22 000 mm Service limit 21 85 mm 19 000 19 120 mm Service limit 18 88 mm Under 0 1 mm Service limit 0 2 mm CN Canada Model US U S Model Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1057 Hook Wrench 57001 1101 Bearing Driver Set 57001 1129 Fork Outer Tube Weight 57001 1218 Jack 57001 1238 Fork Spring Holder 57001 1286 Fork Cylinder Holder 57001 1287 Fork Oil Level Gauge 57001 1290 Fork Piston Rod Puller M10 x 1 0 57001 1298 Hexagon Wrench Hex 29 57001 1335 Fork Oil Seal Driver 043 57001 1340 http mototh com Color Code B K Black B L Blue B R Brown C H C h o c o l a t e D G Dark Green G Green G Y Gray L B Light Blue L G L i g h t Green 0 orange P P in
27. 100 mm Piston Diameter Measure the outside diameter of piston 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin l f the measurement is under the service limit replace the piston Piston Diameter Standard Service Limit 71 970 71 985 mm 71 82mm http mototh com 4 28 ENGINE TOP END Exhaust Pipe Muffler Exhaust Pipe Removal Loosen the clamp bolt A Remove the exhaust pipe holder nuts A Pull off the exhaust pipe to the frontward Muffler Removal Remove the right side cover Loosen the clamp bolt Remove the mounting bolts A and pull off the muffler rearward Exhaust Pipe Muffler Installation Notes Check the exhaust gasket for signs of damage If necessary replace it with a new one Thoroughly warm up the engine wait until the engine cools down and then retighten the clamp bolt and holder nuts http mototh com ENGINE RIGHT SIDE LEFT SIDE 5 1 Engine Right Side Left Side Table of Contents Exploded View 5 2 Specifications 5 4 Clutch Cable 5 5 Adjustment Check 5 5 Clutch Adjustment 5 5 Clutch Cover 5 6 Clutch Cover Removal 5 6 Clutch Cover Installation Notes 5 6 Right Engine Cover 5 7 Removal 5 7 Clutch 5 8 Removal 5 8 Clutch Installation Notes 5 9 Friction and Steel Plate Wear Damage Inspection 5 9 Friction and Steel Plate Warp Inspection 5 10 Clutch Spring Free Length Measurement 5 10 Primary
28. 120 Valve Seat Cutter 32 30 57001 1120 Valve Seat Cutter 45 24 5 57001 1113 Valve Seat Cutter 60 25 57001 1328 Valve Seat Cutter Holder 4 5 57001 1330 Valve Seat Cutter Holder Bar 57001 1128 Piston Pin Puller Assembly 57001 910 http mototh com ENGINE TOP END 4 7 Cylinder Head Cover Removal Remove Side Covers Seat Radiator Covers Fuel Tank Ignition Coil Remove the cylinder head cover bolts A and take off the cover toward the left side B Installation Notes Installation is the reverse of removal Apply silicone sealant to the plug hole A of the cylinder head Tighten the cover bolts Torque Cover Bolts 7 8 N m 0 8 kg m 69 in lb Sealant Kawasaki Bond Silicone Sealant 56019 120 http mototh com 4 8 ENGINE TOP END Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves
29. 1st 3 000 30 10 2nd 2 000 30 15 3rd 1 500 27 18 4th 1 250 25 20 5th 1 050 21 20 6th 0 904 19 21 Final drive system Type Chain drive Reduction ratio 3 000 42 14 Overall drive ratio 7 772 Top gear Frame Type Tubular semi double cradle Caster rake angle 26 5 Trail 109 mm AS 107 mm Front tire Type Tube DUNLOP D603F Size 3 00 21 51 P Rear tire Type Tube DUNLOP D603 Size 4 60 18 63P Front suspension Type Telescopic fork Wheel travel 290 mm Rear suspension Type Swingarm uni trak Wheel travel 280 mm Brake type Front Single disc Rear Single disc Electrical Equipment Battery 12 V 6 Ah Headlight Type Semi sealed beam Bulb 12 V 60 55 W quartz halogen Taillight 12 V 5 21 W Alternator Type Three phase AC Rated output 14 5 A 14 V 6 000 r min rpm Specifications subject to change without notice and may not apply to every country W Swiss Model http mototh com Periodic Maintenance Chart KLX250G SUPPLEMENT FOR 1994 M O D E L 17 5 The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected http mototh com 17 6 SUPPLEMENT FOR 1994 MODEL t For higher odometer readings repeat at the frequency interval established here Replace add adjust clean or torque if ne
30. 6 Chain Case FG Germany Model http mototh com 14 4 FRAME Fender Front Fender Removal Unscrew the mounting bolts A and remove the front fender Front Fender Installation Note Installation is the reverse of removal Rear Fender Front Removal Remove the seat Remove the rear fender front mounting bolts A Remove the rear fender front Rear Fender Front Installation Note Installation is the reverse of removal Rear Fender Rear Removal Remove Seat Side Covers Pull off the turn signal light connectors Unscrew the carrier bolts A and remove the carrier B http mototh com FRAME 14 5 Remove the under cover A by taking off the bolts B C Pull off the license light connectors Remove the rear fender rear section A by taking off the bolts B and nuts C O Pull off the taillight connectors Rear Fender Rear Installation Notes Installation is the reverse of removal Route the leads and coolant reserve tank breather hose according to the cable wire and hose routing in the General Information chapter http mototh com ELECTRICAL SYSTEM 15 1 Electrical System Table of Contents Exploded View 15 2 Specifications 15 5 Precautions 15 6 Electrical Wiring 15 7 Inspection 15 7 KLX250D Wiring Diagram 15 8 KLX250E Wiring Diagram European model 15 9 KLX250E Wiring Diagram Australian model 15 10 Flywheel Magneto 15 11 Stator Re
31. B Stopper C Weight 2 D Lift Pin E http mototh com 4 12 ENGINE TOP END Cylinder Head Compression Measurement Remove Seat Radiator Covers Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running Stop the engine remove the fuel tank and the spark plug and attach the compression gauge special tool A and the adapter hose B firmly into the spark plug hole Special Tool Compression Gauge 57001 221 Compression Gauge Adapter M10 X 1 0 57001 1317 W i t h the throttle fully open turn engine over sharply with the kickstarter several times until the compression gauge stops rising the compression is the highest reading obtainable Cylinder Compression Usable Range 440 735 kPa 4 5 7 5 kg cm 2 6 4 1 2 7 psi l f cylinder compression is higher than the usable range check the following 1 Carbon build up on the piston head and cylinder head clean off any carbon on the piston head and cylinder head 2 Cylinder head gasket cylinder base gasket use only the proper gaskets The use of a gasket of incorrect thickness will change the compression 3 Valve stem oil seals and piston rings rapid carbon accumulation in the combustion chamber may be caused by damaged valve stem oil seals and or damaged piston oil rings This may be indicated by white exhaust smoke 4 Compression release
32. Compressor Assembly 57001 241 http mototh com 1 18 GENERAL INFORMATION Oil Seal Guide 016 57001 263 Oil Seal Guide 013 57001 264 Piston Pin Puller Assembly 57001 910 Hand Tester 57001 983 Fuel Level Gauge 57001 1017 Spark Plug Wrench Hex 18 57001 1024 Fork Cylinder Holder Adapter 57001 1057 Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 Steering Stem Bearing Driver Adapter 57001 1074 http mototh com GENERAL INFORMATION 1 19 Head Pipe Outer Race Press Shaft 57001 1075 Steering Stem Nut Wrench 57001 1100 Head Pipe Outer Race Driver 57001 1076 Piston Ring Compressor Grip 57001 1095 Head Pipe Outer Race Remover 57001 1107 Piston Ring Compressor Belt 67 lt D79 57001 1097 Valve Seat Cutter 45 24 5 57001 1113 Spring Compressor 57001 1087 Head Pipe Outer Race Driver 57001 1106 Hook Wrench 57001 1101 http mototh com 1 20 GENERAL INFORMATION Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 028 57001 1119 Valve Seat Cutter 32 030 57001 1120 Valve Seat Cutter 60 O30 57001 1123 Crankshaft Jig 57001 1174 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 Valve Seat Cutter Holder Bar 57001 1128 Flywheel Puller M30 x 1 5 57001 1191 Bearing Driver Set 57001 1129 Rotor Holder 57001 1184 http mototh com GENERAL INFORMATION 1 21 Valve Spring Compressor Adapter lt P22 57001 1
33. Frame 3 Regulator Rectifier 4 Clamp on the frame 5 Clamp 92037 1069 6 Sidestand Switch 7 Brake Switch 8 Alternator http mototh com FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded View 2 2 Specifications 2 3 Throttle Grip and Cables 2 4 Free Play Inspection 2 4 Free Play Adjustment 2 4 Cable Installation Notes 2 4 Cable Lubrication 2 4 Cable Inspection 2 5 Carburetor 2 6 Idle Speed Inspection 2 6 Idle Speed Adjustment 2 6 Service Fuel Level Inspection 2 7 Service Fuel Level Adjustment 2 7 Fuel System Cleanliness Inspection 2 8 Removal 2 8 Installation Notes 2 9 Disassembly Assembly Notes 2 10 Cleaning 2 10 Inspection 2 11 Air Cleaner 2 12 Housing Removal 2 12 Housing Installation Notes 2 12 Element Removal 2 12 Element Installation Notes 2 12 Element Cleaning and Inspection 2 13 Fuel Tank 2 14 Removal 2 14 Installation Notes 2 14 Inspection 2 14 Cleaning 2 15 Fuel Tap Removal 2 15 Fuel Tap Installation Notes 2 15 Fuel Tap Inspection 2 15 http mototh com 2 2 FUEL SYSTEM Exploded View AD Apply adhesive 1 Jet Needle 2 Pilot Screw 3 Pilot Jet 4 Main Jet 5 Needle Jet Bleed Pipe 6 Fuel Filter 7 Fuel Level Sensor 8 Vacuum Valve http mototh com AR Austria Model NL Netherlands Model FG Germany Model ST Switzerland Model Special Tools Pressure Cable Luber K56019 021 Jack 57001 1238 Pilot Screw Adjuster A 57001 1239 Fuel
34. Gear 5 11 Primary Gear Removal 5 11 Primary Gear Installation Notes 5 11 Kickstarter 5 12 Kickstarter Assembly Removal 5 12 Kickstarter Assembly Installation Notes 5 12 Kickstarter Assembly Disassembly Assembly Notes 5 12 Kickstarter Idle Gear Removal Note 5 13 Kickstarter Idle Gear Installation Notes 5 13 External Shift Mechanism 5 14 Removal 5 14 Installation Notes 5 14 Inspection 5 14 http mototh com 5 2 ENGINE RIGHT SIDE LEFT SIDE Exploded View KLX250D E G Apply Grease L Apply a non permanent locking agent T1 5 4 N m 0 55 kg m 48 in lb T2 9 8 N m 1 0 kg m 87 in lb T3 15 N m 1 5 kg m 11 0 ft lb T4 78 N m 8 0 kg m 58 ft lb T5 3 2 N m 0 33 kg m 29 in lb T6 37 N m 3 8 kg m 27 ft lb http mototh com ENGINE RIGHT SIDE LEFT SIDE 5 3 KLX250D E http mototh com 5 4 ENGINE RIGHT SIDE LEFT SIDE Specifications Item Standard Service Limit Clutch Lever Free Play 2 3 mm Clutch Lever Free Play at lever end 10 20 mm Clutch Friction plate thickness 2 92 3 08 mm 2 7 mm Friction and steel plate warp 0 2 mm or less 0 3 mm Clutch spring free length 32 65 mm 31 0 mm Special Tools Oil Seal Guide 16 57001 263 Oil Seal Guide 13 57001 264 Kick Shaft Okl Seat Guide 57001 267 Pressure Cable Luber K56019 021 Flywheel Holder 57001 1313 Outside Circlip Pliers 57001 144 Sealant Kawasaki Bond Silicone Sealant 56019 120 http mototh com E
35. Installation Notes 4 8 Chain Tension Spring Removal 4 8 Chain Tension Spring Installation 4 8 Camshaft Camshaft Chain 4 9 Camshaft Removal 4 9 Camshaft Installation Notes Including Camshaft Chain Timing Procedure 4 9 Camshaft and Sprocket Assembly Notes 4 10 Camshaft Bearing Oil Clearance Inspection 4 10 Camshaft Chain Wear 4 10 KAWASAKI Automatic Compression Release KACR 4 11 Cylinder Head 4 12 Compression Measurement 4 12 Removal 4 12 Installation Notes 4 13 Warp 4 13 Cleaning 4 14 Valves 4 15 Clearance Inspection 4 15 Clearance Adjustment 4 15 Removal 4 16 Installation 4 16 Guide Removal 4 16 Guide Installation 4 20 Seat Inspection 4 20 Seat Repair 4 20 Seat Cutter Operating Care 4 21 Marks Stamped on the Cutter 4 21 Operating Procedures 4 21 Valve to Guide Clearance Measurement Wobble Method 4 23 Cylinder Piston 4 25 Cylinder Removal 4 25 Cylinder Installation Notes 4 25 Piston Removal 4 25 Piston Installation Notes 4 26 Piston Ring Piston Ring Groove Wear 4 27 Piston Ring End Gap 4 27 Cylinder Inside Diameter 4 27 Piston Diameter 4 27 Exhaust Pipe Muffler 4 28 Exhaust Pipe Removal 4 28 Muffler Removal 4 28 Exhaust Pipe Muffler Installation Notes 4 28 http mototh com 4 2 ENGINE TOP END Exploded View LS Liquid Gasket Silicone Sealant M Molybdenum Disulfide Grease O Engine Oil S Follow the specific tightening sequence T1 7 8 N m 0 80 kg m 69 in l
36. Installation Notes 8 8 Connecting Rod Big End Side Clearance 8 8 Crankshaft Runout 8 9 Crankshaft Alignment 8 9 Balancer 8 10 Balancer Removal 8 10 Balancer Installation Notes 8 10 Transmission 8 11 Shaft Removal 8 11 Shaft Installation Notes 8 11 Shaft Disassembly Note 8 11 Shaft Assembly Notes 8 11 Shift Drum and Fork Installation Notes 8 12 Shift Fork Bending 8 12 Shift Fork Gear Groove Wear 8 13 Shift Fork Guide Pin Shift Drum Groove Wear 8 13 Gear Damage 8 13 Gear Dog Gear Dog Hole Damage 8 14 Ball Bearing Wear 8 14 http mototh com 8 2 CRANKSHAFT TRANSMISSION Exploded View KLX250D E KLX250E G LG L T1 T2 T3 T4 T5 Apply Grease Apply a Liquid Gasket Apply a non permanent locking agent 12 N m 1 2 kg m 8 5 ft lb 25 N m 2 5 kg m 18 ft lb 37 N m 3 0 kg m 27 ft lb 98 N m 10 0 kg m 72 ft lb 9 8 N m 1 0 kg m 87 in lb http mototh com CRANKSHAFT TRANSMISSION 8 3 KLX250D E http mototh com 8 4 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rod Connecting rod big end radial clearance 0 008 0 020 mm 0 07 mm Connecting rod big end side clearance 0 25 0 35 mm 0 6 mm Crankshaft runout TIR 0 03 mm or less TIR 0 10 mm Transmission Shift fork ear thickness 4 4 4 5 mm 4 3 mm Gear shift fork groove width 4 55 4 65 mm 4 8 mm Shift fork guide pin diameter 5 9 6 0 mm 5 8 mm Shift drum gro
37. KLX250D E 1 Relief Valve 2 Oil Pump 3 Engine Oil Drain Plug T1 15 N m 1 5 kg m 11 0 ft lb T2 9 8 N m 1 0 kg m 87 in lb T3 20 N m 2 0 kg m 14 5 ft lb T4 5 4 N m 0 55 kg m 48 in lb http mototh com ENGINE LUBRICATION SYSTEM 6 3 Specifications Item Standard Engine Oil Grade Viscosity Capacity SE or SF class SAE 10W 40 10W 50 20W 40 or 20W 50 1 3 L when filter is not removed 1 4 L when filter is removed 1 5 L when engine is completely dry Oil Pressure Measurement Relief valve opening pressure Oil pressure 4000 r min rpm oil temp 90 C 194 F 430 590 kPa 4 4 6 0 kg cm2 63 85 psi 7 8 1 4 7 kPa 0 8 1 5 kg cm2 11 21 psi Special Tool Oil Pressure Gauge 10 kg cm2 57001 164 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 Oil Pressure Gauge Cap 57001 1361 http mototh com 6 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1 Oil Screen 2 Oil Pump 3 Clutch Cover Oil Passage 4 Oil Filter 5 Crankshaft 6 Oil Pipe Banjo Bolt 7 Camshafts 8 Drive Shaft 9 Output Shaft 10 Camshaft Chain Tunnel http mototh com ENGINE LUBRICATION SYSTEM 6 5 Engine Oil and Oil Filter AWARNiNG Motorcycle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure accident and injury Oil Level Inspection l f the oil has just been changed start the engine and
38. PS 8500 r min rpm US 22 4 KW 30 5 PS 8500 r min rpm Maximum torque 26 5 N m 2 7 kg m 19 5 ft lb 7500 r min rpm US 25 3 N m 2 6 kg m 19 0 ft lb 7500 r min rpm Carburetion system Carburetor KEIHIN CVK32 Starting system Primary kick Ignition system CDI Timing advance Electronically advanced Ignition timing From 5 BTDC 1700 r min rpm to 40 BTDC 3000 r min rpm Spark plug NGKCR8E NDU24ESR N Cylinder numbering method Firing order Valve timing Inlet Open 22 BTDC Close 62 ABDC Duration 264 Exhaust Open 61 BBDC Close 19 ATDC Duration 260 Lubrication system Forced lubrication wet sump Engine oil Grade SE SF or SG class Viscosity SAE10W 40 10W 50 20W 40 or 20W 50 Capacity 1 5 L http mototh com GENERAL INFORMATION 1 7 Items KLX250 D1 D2 D3 D4 Drive Train Primary reduction system Type Reduction ratio Clutch type Transmission Type Gear ratios 1 st 2nd 3rd 4th 5th 6th Final drive system Type Reduction ratio Overall drive ratio Gear 2 863 63 22 Wet multi disc 6 speed constant mesh return shift 3 000 30 10 2 000 30 15 1 500 27 18 1 250 25 20 1 050 21 20 0 904 19 21 Chain drive 3 571 50 14 9 253 Top gear Frame Type Caster rake angle Trail Front tire Type Size Rear tire Type Size Front suspension Type Wheel travel Rear suspension Type Wheel travel Brak
39. SUSPENSION 12 15 Assembly Oil Change Notes Replace the following with new ones Dust Seal A Retaining Ring B Oil Seal C Guide Bushings D Place an oil coated plastic bag E over the end of the inner tube to protect the oil seals OThe inner tube bushing groove has a sharp edge that can cut the sealing lip of the seals as they are pushed down over the inner tube Install in order these parts on the inner tube When assembling the new outer tube guide bushing A hold the washer B against the new bushing and tap the washer with the fork oil seal driver C until it stops Special Tool Fork Oil Seal Driver 0 gt 43 57001 1340 After installing the washer install the oil seal by using the fork oil seal driver Check the O rings A on the cylinder valve assembly B and replace them with new ones if damaged Replace the gasket C with a new one Insert the cylinder unit into the inner tube all the way down A p p l y a non permanent locking agent to the threads D of the cylinder valve assembly and screw the valve assembly into the bottom of the cylinder unit Hold the cylinder unit with the fork cylinder holder and tighten the cylinder valve assembly Special Tool Fork Cylinder Holder 57001 1287 Torque Cylinder Valve Assembly 54 N m 5 5 kg m 40 ft lb Install the spring guide C so that the taper end is down and install the collar B Install the
40. Screw the oil pressure gauge adapter P N 57001 1182 in the cap and install the oil pressure gauge hose P N 57001 164 in the gauge adapter Special Tool Oil Pressure Gauge 10 kg cm2 57001 164 Oil Pressure Gauge Cap 57001 1361 A Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 B http mototh com ENGINE LUBRICATION SYSTEM 6 9 Start the engine and read the oil pressure gauge while running engine at various speeds A normal relief valve keeps the maximum oil pressure between the specified values Relief Valve Opening Pressure 430 590 kPa 4 4 6 0 kg cm2 63 85 psi Stop the engine Remove the oil pressure gauge and adapter l f the reading is much higher than the specifications the relief valve is stuck in its closed position l f the reading is much lower than the specifications the relief valve may be stuck open or there may be other damage in the lubrication system Stop the engine immediately and find the cause When the engine is warmed up Warm up the engine and then stop the engine Install the oil pressure gauge and adapter as shown above Start the engine again Run the engine at the specified speed and read the oil pressure gauge Stop the engine Remove the oil pressure gauge and adapter l f the oil pressure is significantly below the specification inspect the oil pump and relief valve Oil Pressure 78 147 kPa 0 8 1 5 kg cm2 11 21 psi
41. Start Starting Difficulty 16 4 Poor Running at Low Speed 16 4 Poor Running or No Power at High Speed 16 5 Overheating 16 5 Over Cooling 16 5 Clutch Operation Faulty 16 5 Gear Shifting Faulty 16 6 Abnormal Engine Noise 16 6 Abnormal Drive Train Noise 16 6 Abnormal Frame Noise 16 6 Exhaust Smokes Excessively 16 6 Handling and or Stability Unsatisfactory 16 7 Brake Doesn t Hold 16 7 Nut Bolt and Fastener Tightness 16 8 Tightness Inspection 16 8 General Lubrication 16 9 Lubrication 16 9 Unit Conversion Table 16 10 Prefixes for Units 16 10 Units of Mass 16 10 Units of Volume 16 10 Units of Force 16 10 Units of Length 16 10 Units of Torque 16 10 Units of Pressure 16 10 Units of Speed 16 10 Units of Power 16 10 Units of Temperature 16 10 http mototh com 16 2 APPENDIX Additional Considerations for Racing KLX250E This motorcycle has been manufactured for use in a reasonable and prudent manner and as a vehicle only However some may wish to subject this motorcycle to abnormal operation such as would be experienced under racing conditions KAWASAKI STRONGLY RECOMMENDS THAT ALL RIDERS RIDE SAFELY AND OBEY ALL LAWS AND REGULATIONS CONCERNING THEIR MOTORCYCLE AND ITS OPERATION Racing should be done under supervised conditions and recognized sanctioning bodies should be contacted for further details For those who desire to participate in competitive racing or related use the fol
42. and recheck the oil level Route the cables and hose according to the Cable Wire and Hose Routing ssction in the General Information chapter http mototh com SUSPENSION 12 7 Front Fork Removal Remove the caliper from the fork teg to be removed and rest the caliper on some kind of stand so that it does not dangle Remove the front wheel see Front Wheel RemovaJ in the Wheels Tires chapter Loosen the upper A and lower B fork clamp bolts W i t h a twisting motion work the fork leg down and out Front Fork Installation Notes Installation is the reverse of removal If the fork leg was disassembled check the fork oil level Route the cables and hose according to the Cable Wire and Hose Routing section in the General Information chapter Tighten the lower and upper damp bolts Torque Clamp Bolts Lower 20 N m 2 0 kg m 14 5 ft lb Upper 20 N m 2 0 kg m 14 5 ft lb Tighten the axle nut Torque Front Axle Nut 88 N m 9 u kg m 65 ft lb Tighten the caliper mounting bolts Torque Caliper Mounting Bote 25 N m 2 5 kg m 18 ft lb Check the front brake operation after installation Front Fork Disassembly Remove Front Fork Dust Boot A Top Plug Pull out the spacer spring seat and spring Check the 0 rings of the top plugs for damage If necessary replace them Pour the fork oil into a container Clean the bottom of the outer tube
43. at the tire balance mark A the chalk mark made during removal or the yellow paint mark on a new tire Tighten the bead protector nut securely Check and adjust the air pressure after installing WHEELS TIRES 9 9 http mototh com 9 10 WHEELS TIRES Hub Bearings Removal Notes CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Remove the circlip Special Tool Inside Circlip Pliers 57001 143 Remove the hub bearing by tapping evenly around the bearing inner race as shown 1 Bar A 2 Distance Collar B 3 Hub Bearing C Installation Notes Install the new circlip Special Tool Inside Circlip Pliers 57001 143 Before installing the wheel bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings Replace the bearings with new ones Lubricate and install them using the bearing driver set A so that the marked or sealed sides face out Special Tool Bearing Driver Set 57001 1129 Replace the grease seals with new ones Press the grease seal in until it stops at the circlip in the hole using the same special tools used for bearing installation Inspection NOTE Olt is not necessary to remove any bearings for inspection If Any bearings are removed they will need to be replace
44. brake for good braking power no brake drag and no fluid leakage http mototh com Caliper BRAKES 11 9 Front Caliper Removal Remove the front brake hose clamp mounting bolts Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Remove the plug and loosen the brake pad bolt E before the caliper removal if the caliper is to be disassembled NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before brake hose removal see Disassembly Unscrew the mounting bolts B and detach the caliper C from the disc Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wipe up any brake fluid that spills Rear Caliper Removal Remove Banjo Bolt A Rear Axle Take off the caliper B along with the caliper bracket C NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available remove the piston using the following steps before disconnecting the brake hose from the caliper O Remove the pads O Pump the brake pedal to remove the piston CAUTION Immediately wipe up any brake fluid that spills Installation Notes Tighten the brake pad bolt if it was removed Torque Brake Pad Bolt 18 N m 1 8 kg m 13 tt lb Install the caliper and the brake hose lower end O Replace t
45. carburetor and recheck the fuel level l f the fuel level cannot be adjusted by this method the float or the float valve is damaged Fuel System Cleanliness Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine KLX250D or turn the ignition switch OFF KLX250E Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Turn the fuel tap to the OFF position Run the lower end of the overflow hose from the float bowl into a suitable container Turn out the drain screw A a few turns and drain the fuel from the carburetor Check to see if water or dirt comes out l f any water or dirt comes out clean the fuel system see Carburetor cleaning and Fuel Tank cleaning Tighten the drain screw securely Removal AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine KLX250D or turn the ignition switch OFF KLX250E Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Turn the fuel tap to the OFF position and pull the fuel hose off the tap Drain the fuel from the carburetor by turning out the drain screw a few turns Remove the right radiator cover and then throttle cable lower ends http mototh co
46. carburetor adjustment Open and close the throttle a few times to make sure that the idle speed does not change Readjust if necessary http mototh com FUEL SYSTEM 2 7 Service Fuel Level Inspection Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine KLX250D or turn the ignition switch OFF KLX250E Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light T u rn the fuel tap to the OFF position Remove the carburetor and hold it upright on a stand see Carburetor Removal Prepare an auxiliary fuel tank and connect the fuel hose to the carburetor Connect a fuel level gauge A to overflow hose F Special Tool Fuel Level Gauge 57001 1017 Hold the gauge vertically against the side of the carburetor body so that the zero line B is several millimeters higher than the float bowl mating surface D T u rn the fuel tap to the ON position to the carburetor then turn out the carburetor drain screw C a few turns W a i t until the fuel level in the gauge settles Keeping the gauge vertical slowly lower the gauge until the zero line is even with the bottom edge of the carburetor body NOTE ODo not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measured shows
47. from the top plug and hold it there throughout the following procedure Pull down the fork spring A and slip the fork spring holder B in on top of the spring seat and under the push rod nut C Special Tool Fork Spring Holder 57001 1286 Use wrenches on the rod nut and the top plug A to loosen the rod nut Remove the top plug from the push rod Remove the fork spring holder Lift the fork spring B and its top spring seat C out of the inner tube Hold the fork tube upside down over a clean container and pump it to drain the oil NOTE O To discharge the fork oil pump the push rod A up and down ten times http mototh com 12 12 SUSPENSION Hold the fork tube upright press the outer tube and the push rod all the way down NOTE O The spring should not be installed Fill the front fork to the top with the specified oil Recommended Oil KAY ABA 01 or SAE5W NOTE O While doing this take care to keep the oil level topped off so that it stays above the two large holes A near the top of the inner tube ffl Purge the air from the fork cylinder by gently moving the rod puller A up and down five times Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 Purge the air from between the inner and outer tubes by pumping the outer tube up and down After purging the air from the assembly let it sit for about five minutes so that any suspended air bubbles
48. is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see the Electrical System chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battervs performance may be reduced noticeably if charged under conditions other than given above Never remove the sealing plug during refresh charge If by chance an excessive amount of gas is generated due to overcharging the safety valve operates to keep the battery safe 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative lead removed Give a refresh charge every six months during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has exceeded it s useful life Replace it Provided however the vehicle s starting system has no problem AWARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the
49. kg m 29 It lb Tie Rod Mounting Nut 81 N m 8 3 kg m 60 ft lb Rocker Arm Pivot Nut 98 N m 10 0 kg m 72 ft lb Spring Replacement In addition to the standard spring of the KLX250D heavy and light springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions Remove the rear shock absorber Clean the threaded portion on the upper end of the rear shock absorber Hold the upper end of the rear shock absorber in a vise Using the hook wrenches C loosen the locknut B and turn the adjusting nut A all the way up Special Tool Hook Wrench 57001 1101 Slide down the rubber bumper Remove the spring guide A from the shock absorber and lift off the spring B Exchange the spring for an optional part Install the spring so that the smaller diameter end A faces upward Install the spring guide Adjust the spring preload see Spring Preload Adjustment Install the rear shock absorber Install the parts removed http mototh com SUSPENSION 12 21 Disassembly Oil Change KLX250D The oil in the rear shock absorber should be changed at least once per racing season The frequency for best performance must be based upon riding conditions and rider ability Remove the rear shock absorber from the frame see Rear Shock Absorber Removal Remove the shock absorber spring see Spring Replacem
50. plug incorrect CDI unit trouble Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct poorly sealed Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brakes dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Coolant temperature warning light incorrect Coolant temperature warning light broken KLX250E Water temperature sensor broken KLX250E Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Thermostat trouble KLX250E Radiator cap trouble Thermostatic fan switch trouble KLX250E Fan relay trouble KLX250E Fan motor broken KLX250E Fan blade damaged KLX250E Water pump not rotating Water pump impeller damaged Over Cooling Cooling system component incorrect Thermostatic fan switch trouble KLX250E Thermostat trouble KLX250E Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted Clutch inner cable catching http mototh com 16 6 APPENDIX Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Cl
51. reach is too long carbon will build up on the exposed spark plug threads causing overheating preigniton and possibly burning a hole in the piston top In addition it may be impossible to remove the plug without damaging the cylinder head Standard Spark Plug Threads Diameter 12 mm Pitch 1 25 mm Reach 19 mm NOTE O The heat range of the spark plug functions like a thermostat for the engine Using the wrong type of spark plug can make the engine run too hot resulting in engine damage or too cold with poor performance misfiring and stalling APPENDIX 16 3 http mototh com 16 4 APPENDIX Troubleshooting Guide NOTE O This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Balancer bearing seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Compression release cam spring broken K A C R Compression release cam sticks close K A C R No fuel flow No fuel in fuel tank Fuel tap turned off Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level in carburetor float bowl too high Float valve worn or
52. run it for several minutes at idle speed This fills the oil filter with oil Stop the engine CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the motorcycle has just been used wait several minutes for all the oil to drain down Situate the motorcycle so that it is perpendicular to the ground and check the engine oil level through the oil level gauge B The oil level should come up between the upper C and lower D level lines l f the oil level is too high remove the excess oil using a syringe or some other suitable device l f the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and makes of oil that is already in the engine NOTE Olf the engine oil type and makes are unknown use any brand of the specified oil to top off the level rather than running the engine with the oil level low Then at your earliest convenience change the oil completely Oil and or Oil Filter Change Warm up the engine so that the oil will pick up any sediment and drain easily and stop the engine Place an oil pan beneath the engine Remove the engine drain plug A and let the oil drain completely NOTE O Hold the motorcycle upright so that the oil may drain completely http mototh com 6 6 ENGINE LUBRICATION SYSTEM If the oil filter is to be changed replace it with a new one Check the gasket at the d
53. shock absorber in a vise Using the hook wrenches A loosen the locknut B and turn the adjusting nut C as required Turning the adjusting nut down makes the spring preload stronger Special Tool Hook Wrench 57001 1101 Spring Preload Adjustment KLX250D Adjusting nut position A from the center of the mounting hole Standard 115 5 mm 4 55 in Adjustable Range 106 128 mm 4 16 5 04 in Tighten the locknut securely After adjusting move the spring up and down to make sure that the spring is seated Install the parts removed Removal Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 Remove Side Cover Seat Remove the engine bottom guard C Remove the tie rod front mounting bolt A Remove the rear shock absorber lower mounting nut B CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolts sleeve and bearing Remove the rocker arm pivot bolt C OTake out or push down the rocker arm D Remove the rear shock absorber upper mounting bolt A and pull the rear shock absorber B down SUSPENSION 12 19 http mototh com 12 20 SUSPENSION Then pull up and take out the rear shock absorber A from the left side of the frame Installation Notes Torque the following Torque Rear Shock Absorber Mounting Nuts 39 N m 4 0
54. smoothly 11 Ball Bearing and Needle Bearing Do not remove any ball or needle bearings that are pressed in unless it is necessary If they are removed replace them with new ones When installing a bearing press it in with the marked side facing out using a suitable driver until it is bottomed Bearings should be pressed into place by pushing evenly the bearing race which is affected by friction http mototh com GENERAL I N F O R M A T I O N 1 3 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 15 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks
55. somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel into a suitable container and start the procedure over again Read the fuel level E in the gauge and compare to the specification Screw in the carburetor drain screw T u r n the fuel tap to the OFF position and remove the fuel level gauge l f the fuel level is incorrect adjust it see Service Fuel Level Adjust ment Service Fuel Level above the bottom edge of ihe carburetor body Standard 0 5 1 mm Sen ice Fuel Level Adjustment Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine KLX250D or turn the ignition switch OFF KLX250E Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the carburetor and drain the fuel into a suitable container Remove the float bowl Drive out the pilot pin A and remove the float B http mototh com 2 8 FUEL SYSTEM Bend the tang A on the float arm very slightly to change the float height O Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard 17 0 mm NOTE ODo not push the needle rod B in during the float height measure ment A Float Bowl Mating Surface B Float Valve Needle Rod C Float D Float Height Assemble the
56. the amount of friction or steel plate warp l f any plate is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard not more than 0 2 mm Service Limit 0 3 mm Clutch Spring Free Length Measurement Since the spring A becomes shorter as it weakens check its free length to determine its condition l f any of the spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 32 65 mm Service Limit 31 0 mm http mototh com ENGINE RIGHT SIDE LEFT SIDE 5 11 Primary Gear Primary Gear Removal Remove the right engine cover see Right Engine Cover Removal Remove the clutch see Clutch Removal Using the flywheel holder to prevent the primary gear A from rotating loosen the primary gear nut B Remove the primary gear nut and primary gear There is a woodruff key between the primary gear and crankshaft Special Tool Flywheel Holder 57001 1313 Primary Gear Installation Notes Installation is the reverse of removal Fit the woodruff key A on the primary gear groove B of the crankshaft Do not tap the primary gear A onto the crankshaft with a hammer Install the conical spring washer so that the concave surface faces B toward the gear Using the flywheel holder to prevent the clutch housing and primary gears from rotating tighten the primary gear nut Torque Primary Gear Nut 98 N m 10
57. the carbon will collect on the electrodes and the ceramic insulator The carbon on the electrodes conducts electricity and can short the center electrode to ground by either coating the ceramic insulator or bridging across the gap Such a short will prevent an effective spark Carbon build up on the plug can also cause other troubles It can heat up red hot and cause preignition and knocking which may eventually burn a hole in the top of the piston Spark Plug Inspection Remove the spark plug and inspect the ceramic insulator Whether or not the right temperature plug is being used can be ascer tained by noting the condition of the ceramic insulator around the electrode A light brown color indicates the correct plug is being used If the ceramic is black it indicates that the plug is firing at too low a temperature so the next hotter type should be used instead If the ceramic is white the plug is operating at too high a temperature and it should be replaced with the next colder type CAUTION If the spark plug is replaced with a type other than the standard plug make certain the replacement plug has the same thread pitch and reach length of threaded portion and the same type electrode regular type or projected type as the standard plug H the plug reach is too short carbon will build up on the plug hole threads in the cylinder head causing overheating and making it very difficult to insert the correct spark plug later If the
58. the crankshaft Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm Service Limit 0 6 mm http mototh com CRANKSHAFT TRANSMISSION 8 9 Crankshaft Runout Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge against the points indicated Turn the crankshaft slowly The maximum difference in gauge readings is the crankshaft runout l f the runout at either point exceeds the service limit align the flywheels so that the runout falls within the service limit Crankshaft Runout Standard Not more than 0 03 mm Service Limit 0 05 mm Crankshaft Alignment In case of horizontal misalignment which is the most common strike the projecting rim of the flywheel with a plastic soft lead or brass hammer as indicated in the figure Recheck the runout with a dial gauge repeating the process until the runout falls within the service limit O Vertical misalignment is corrected either by driving a wedge in between the flywheels or by squeezing the flywheel rims in a vise depending on the nature of the misalignment In cases of both horizontal and vertical misalignment correct the horizontal misalign ment first CAUTION Don t hammer the flywheel at the point A l f flywheel misalignment cannot be corrected by the above method replace the crankpin or the crankshaft itself http mototh com 8 10 CRANKSHAFT TRANSMISSION Balancer Balancer Removal S
59. them 16 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease M0S2 in the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color 18 Replacement Parts When there is a replacement instruction replace these parts with new ones ev
60. 11 14 Assembly Notes 11 15 Inspection Visual Inspection 11 15 Brake Disc 11 16 Inspection 11 16 Brake Hose 11 17 Removal Installation Notes 11 17 Inspection 11 17 BRAKES 11 1 http mototh com 11 2 BRAKES Exploded View KLX250D E G Apply grease T1 7 8 N m 0 80 kg m 69 In lb 72 8 8 N m 0 90 kg m 78 In lb T3 25 N m 2 5 kg m 18 0 ft lb T4 1 5 N m 0 15 kg m 13 in lb T5 5 9 N m 0 6 kg m 52 in lb T6 9 8 N m 1 0 kg m 87 in lb T7 23 N m 2 3 kg m 16 5 ft lb T8 17 N m 1 75 kg m 12 7 ft lb http mototh com BRAKES 11 3 KLX250D E http mototh com 11 4 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake lever free play Pedal free play Adjustable to suit rider Non adjustable Brake Fluid Grade Brand recommended D O T 4 Castrol Girling Universal Castrol GT LMA Castrol Disc Brake Fluid Check Shock Premium Heavy Duty Brake Pads Lining thickness Front Rear 3 8 mm 4 7 mm 1 mm 1 mm Brake Disc Thickness Front KLX250D KLX250E Rear Runout 2 85 3 15 mm 3 35 3 65 mm 4 35 4 65 mm 0 12 mm or less 2 5 mm 2 8 mm 3 8 mm 0 3 mm Special Tools Inside Circlip Pliers 57001 143 Jack 57001 1238 http mototh com BRAKES 11 5 Brake Lever Brake Pedal Lever Play Adjustment Adjust the front brake lever A to suit you Loosen the adjuster locknut B and turn the adjuster C to either sid
61. 202 Pilot Screw Adjuster A 57001 1239 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Timing Light 57001 1241 Fork Outer Tube Weight 57001 1218 Front Fork Oil Seal Driver 57001 1219 Spark Plug Wrench Hex 16 57001 1262 Jack 57001 1238 Bearing Remover Shaft 57001 1265 http mototh com 1 22 GENERAL INFORMATION Bearing Remover Head 010 x 012 57001 1266 Fork Piston Rod Puller M10 x 1 0 57001 1298 Fork Spring Holder 57001 1286 Fork Cylinder Holder 57001 1287 Fork Oil Level Gauge 57001 1290 Bearing Remover Head 015 x 017 57001 1267 Flywheel Holder 57001 1313 Compression Gauge Adapter M10 X 1 0 57001 1317 Valve Seat Cutter 60 025 57001 1328 http mototh com GENERAL INFORMATION 1 23 Cable Wire and Hose Routing Model KLX250D 1 Reservoir Tank Hose 2 Tie laps 3 Clamps 1 Headlight 2 To Right Handlebar Switch 3 To Engine Stop Switch 4 Clamp located on left top radiator 5 Damper 6 Ignition Coil 7 Main Harness 8 To Headlight 9 Tie lap 10 Main Harness 11 Position Mark of Main Horn Locate the mark on this position 12 Regulator 13 Clamp tightened to frame with regulator 14 IC Igniter 15 Position main harness with clamp 16 Tighten clamp together with tail brake light 17 Tail Brake Light http mototh com 1 24 GENERAL INFORMATION M o d e l KLX250E F 1 Throttle Cable 2 Speedometer Cable 3 Clutch Cable 4 Front Brake Hose A
62. 4 000 r min rpm 90 C 194T of oil temp l f the oil pump and relief valve are not at fault inspect the rest of the lubrication system http mototh com 6 10 ENGINE LUBRICATION SYSTEM Oil Pump Inspection Disassemble the oil pump Visually inspect the oil pump body A outer B and inner C rotors and cover D l f there is any damage or uneven wear replace the rotors or the oil pump assembly Relief Valve Inspection Remove the relief valve Check to see if the steel ball inside the valve slides smoothly when pushing it in with a wooden or other soft rod and see if it comes back to its seat by valve spring pressure NOTE O Inspect the valve in its assembled state may change the valve performance Disassembly and assembly l f any rough spots are found during above inspection wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air WARNING Clean the parts in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents l f cleaning does not solve the problem replace the relief valve as an assembly The relief valve is precision made with no allowance for replacement of individual parts http mototh com Oil Screen ENGINE LUBRICATION S Y S T E M 6 11 Removal
63. 50D E G Apply grease AD Apply adhesive Tl 25 N m 2 5 kg m 18 0 ft lb T2 44 N m 4 5 kg m 33 ft lb T3 3 9 N m 0 4 kg m 35 In lb http mototh com STEERING 13 3 Specifications Special Tools Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 57001 1074 Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 57001 1076 Steering Stem Nut Wrench 57001 1100 Head Pipe Outer Race Driver 57001 1106 Head Pipe Outer Race Remover 57001 1107 Jack 57001 1238 http mototh com 13 4 STEERING Steering Inspection Place the jack under the engine so that the front wheel is raised off the ground Special Tool Jack 57001 1238 With the front wheel pointing straight ahead alternately nudge each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop f the steering binds or catches before the stop check the routing of the cables hoses and harnesses l f the steering feels tight adjust or lubricate the steering Feel for steering looseness by pushing and pulling the forks l f you feel looseness adjust the steering Adjustment Place the jack under the engine so that the front wheel is raised off the ground Special Tool Jack 57001 1238 Remove the handlebar Loosen the front fork lower clamp bolts A and steering stem head nut B Turn the steering stem
64. 7 Black smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner poorly sealed or missing Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing race dented or worn Steering stem lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm sleeve or needle bearing damaged Rim warped or not balanced Front rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem head nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Steering stem bent Front fork leg bent Right and left front fork oil level uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Front fork damper adjustment too hard Upside down type Front fork leg bent Tire air pressure too high Rear shock absorber adj
65. 87 in lb Exhaust Pipe Holder Nuts 25 2 5 18 0 Clutch Cover Bolts 9 8 1 0 87 in lb Clutch Cable Mounting Bolts 9 8 1 0 87 in lb Right Engine Cover Bolts 9 8 1 0 87 in lb Magneto Cover Bolts 9 8 1 0 87 in lb http mototh com FFFaaasssttteeennneeerrr Torque RRReeem m maaarrrkkksss N m kg m ft lb Engine Lubrication System Engine Oil Drain Plug Oil Pressure Relief Valve Oil Pipe Banjo Bolts 08 10 Oil Pump Mounting Screws 15 15 9 8 20 5 4 1 5 1 5 1 0 2 0 0 55 11 0 11 0 87 in lb 14 5 48 in lb L Engine Removal Installation Swing Arm Pivot Shaft Nut Engine Mounting Nuts Cylinder Head Bracket Bolts 08 010 88 44 29 44 9 0 4 5 3 0 4 5 65 33 22 33 Crankshaft Transmission Shift Drum Bearing Retaining Bolts Crankcase Bolts 9 8 9 8 1 0 1 0 87 in lb 87 in lb Wheel Tires Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut Spoke Nipples 88 9 8 98 Not less than 1 5 9 0 1 0 10 0 Not less than 0 15 65 87 in lb 72 Not less than 13 in lb Final Drive Rear Sprocket Nuts Swing Arm Pivot Shaft Nut Tie Rod Upper Mounting Nut Rear Axle Nut 29 88 81 98 3 0 9 0 8 3 10 0 22 65 60 72 Brakes Brake Hose Banjo Bolts Front Reservoir Cap Screws Brake Lever Pivot Locknut Front Master Cylinder Clamp Bolts Caliper Bleed Valves Front Rear Front Brake Disc Mounting Bolts Rear Brake Disc Mounting Bolts Caliper Mounting Bolts Fr
66. Brake Fluid D O T 3 Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heacy Duty Wagner Lockheed Heavy Duty Castrol Girling Universal Castrol GT LMA Castrol Disc Brake Fluid Recommended Brake Fulld D O T 4 Castol Girling Universal Castol GT LMA Castrol Disc Brake Fluid Check Shock Premium Heavy Duty http mototh com Suspension 15 Exploded View Upside Down Type G Apply Grease L Apply a non permanent Gasket M Apply Molybdenum Disulfide Grease LG Apply Liquid Gasket T1 9 8 N m 1 0 kg m 87 in lb T2 13 N m 1 3 kg m 9 5 ft lb T3 20 N m 2 0 kg m 14 5 ft lb T4 23 N m 2 3 kg m 16 5 ft lb T5 29 N m 3 0 kg m 22 ft lb T6 39 N m 4 0 kg m 29 ft lb T7 54 N m 5 5 kg m 40 ft lb T8 81 N m 8 3 kg m 60 ft lb T9 88 N m 9 0 kg m 65 ft lb T10 98 N m 10 0 kg m 72 ft lb http mototh com 16 http mototh com Specifications Item Standard Front Fork per one unit Fork inner tube diameter Air Pressure Compression damper setting Fork oil viscosity Fork oil capacity Fork oil level Fork spring free length Rear Shock Absorber Rebound damper set Compression damper set Spring setting position Gas pressure Oil type Oil capacity Spring free length Rocker Arm Sleeve outside diameter Long Short Bolt runout 43 mm Atmospheric pressure Non adjustable 12th click from the first click of the fully clockwised position KAYABA
67. Cam Height Measurement Camshaft Runout http mototh com ENGINE TOP END 4 5 Item Standard Service Limit Valve seat surface Width Exhaust 0 5 1 0 mm Inlet 0 5 1 0 mm Outside diameter Exhaust 24 4 24 6 mm Inlet 28 4 28 6 mm Valve spring free length Outer 41 4 mm 39 7 mm Inner 38 5 mm 36 8 mm Cylinder Piston Cylinder inside diameter 72 000 72 012 mm 72 1 mm Piston diameter 71 970 71 985 mm 71 82 mm Piston cylinder clearance 0 035 0 062 mm Piston ring groove clearance Top 0 03 0 07 mm 0 17 mm Second 0 03 0 07 mm 0 17 mm Piston ring groove width Top 1 02 1 04 mm 1 12 mm Second 1 02 1 04 mm 1 12mm Oil 2 01 2 03 mm 2 11 mm Piston ring thickness Top 0 97 0 99 mm 0 9 mm Second 0 97 0 99 mm 0 9 mm Piston ring end gap Top 0 20 0 35 mm 0 7 mm Second 0 20 0 35 mm 0 7 mm Oil 0 2 0 7 mm 1 0 mm Valve Head Valve Stem Bend http mototh com 4 6 ENGINE TOP END Special Tools Piston Ring Pliers 57001 115 Compression Gauge 57001 221 Compression Gauge Adapter M10 X 1 0 57001 1317 Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 22 57001 1202 Valve Guide Arbor 04 5 57001 1331 Valve Guide Reamer 4 5 57001 1333 Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 28 57001 1119 Valve Seat Cutter 60 30 57001 1123 Kawasaki Bond Silicone Sealant 56019
68. E O Do not hammer Press down evenly with both hands CAUTION Once you installed the strip of caps after filling the battery never remove it nor add any water or electrolyte 1 Strip of Caps V Initial Charge While a maintenance free battery can be used after only filling with electrolyte a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below where an initial charge is required before use However if a battery shows a terminal voltage of higher than 12 5 V after 10 minutes of filling Note 1 no initial charge is necessary Condition requiring initial charge Charging method At low temperatures lower than 0 C 0 7 A x 2 3 hours Battery has been stored in high temperature and humidity 000 777 AAA xxx 111555 222000 hhhooouuurrrsss Seal has been removed or broken peeling tear or hole If you did not hear the air sucking sound Shoosh as you removed the seal Battery as old as 2 years or more after manufacture Battery manufacturing date is printed on battery top Example 12 10 90 T1_ Day Month Year Mfg location Note 1 Terminal voltage To measure battery terminal voltage use a digital voltmeter http mototh com 17 10 SUPPLEMENT FOR 1994 MODEL VI Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the sealing plug to add water
69. ING Steering Maintenance Stem Bearing Lubrication Remove the steering stem Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt Visually check the outer races and the roller Replace the bearing assemblies if they show wear or damages Pack the upper and lower tapered roller bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races Install the steering stem and adjust the steering see Steering Stem Installation Steering Adjustment Stem Warp Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness l f the steering stem shaft is bent replace the steering stem http mototh com FRAME 14 1 Frame Table of Contents Exploded View 14 2 Fender 14 4 Front Fender Removal 14 4 Front Fender Installation Note 14 4 Rear Fender Front Removal 14 4 Rear Fender Front Installation Note 14 4 Rear Fender Rear Removal 14 4 Rear Fender Rear Installation Notes 14 5 http mototh com 14 2 FRAME Exploded View KLX250E KLX250D E 1 Side Cover Pads R H 2 Side Cover Pad L H http mototh com FRAME 14 3 KLX250D E KLX250E 3 Head Light Cover Seal 4 Air Cleaner Case 5 Speedometer Cable Clamp
70. ION When handing the quartz halogen bulbs never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode Install the dust cover so that the stepped portion A point lower and the cover fits onto the bulb Check the headlight aim after installation Headlight Unit Removal Installation Note Install the headlight unit so that the TOP mark A on the lens points up Taillight Bulb Replacement Notes Insert the new bulb by aligning the pins with the grooves in the walls of the socket so that the pin closest to the bulb base A is to the upper right http mototh com 15 24 ELECTRICAL SYSTEM Headlight Lens Removal I Installation Note Be careful not to overtighten the lens mounting bolts A Turn Signal Inspection KLX250E Remove the turn signal relay Connect one 12 V battery and turn signal lights as indicated in the figure and count how many times the lights flash for one minute l f the lights do not flash as specified replace the turn signal relay Testing Turn Signal The Number of Turn Signal Lights Wattage W Flashing Times c m 1 21 23 Light stays on 2 42 46 75 95 Cycle s per minute Condenser Inspection KLX250E Remove the connector of condenser A Set the hand tester to the x 1kQ range connect the tester to the terminals in the condenser unit lead
71. Kawasaki KLX250R KLX250 Motorcycle Service Manual Kawasaki Heavy Industries Ltd 1993 1994 1996 Third Edition 2 Jul 29 1997 K http mototh com LIST OF ABBREVIATIONS A ampere s lb pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s This warning may apply to any of the following components or any assembly containing one or more of these components Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS Operate if possible out of doors or in a well ventilated place Preferably use hand tools or low speed tools equipped if necessary with an appropriate dust extraction facility If high speed tools are used they should always be so equipped If possible dampen before cutting or drilling Dampen dust and place it in properly closed receptacle and dispose of it safely Read OWNER S MANUAL before operating http mototh com Foreword
72. Level Gauge 57001 1017 KLX250E KLX250D FUEL SYSTEM 2 3 Specifications http mototh com 2 4 FUEL SYSTEM Throttle Grip and Cables Free Play Inspection Check the throttle grip free play Throttle Grip Free Play Standard 2 3 mm l f the free play is improper adjust the throttle cable Free Play Adjustment Loosen the locknut A Turn the adjuster B until the proper amount of throttle grip free play is obtained Tighten the locknut l f the proper amount of free play cannot be obtained by using the adjuster only use the nuts on the lower end of the accelerator cable Loosen the locknut and screw the adjuster at the upper end of the accelerator cable all the way in Tighten the locknut securely Remove the right radiator cover Use the upper nut A and lower nut B at the decelerator cable D until there is no clearance between the cable and adjuster E when the throttle grip is completely closed Tighten the nuts Loosen the upper nut A and turn out the lower nut B on the lower end of the accelerator cable C then turn the upper nut in until the proper amount of throttle grip free play is obtained Tighten the nuts securely l f the proper amount of free play cannot be obtained in the adjustable range of the lower adjuster use the adjuster at the upper end of the accelerator cable again Cable Installation Notes Install the throttle cables in accordance wi
73. NGINE RIGHT SIDE LEFT SIDE 5 5 Clutch Cable Due to friction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accordance with the Periodic Maintenance Chart To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment Adjustment Check Slide the dust cover A at the clutch cable upper end out of place Check that the clutch cable upper end is fully seated in the adjuster B Check that the clutch lever C has 10 20mm D of play as shown in the figure l f it does not adjust the lever play Clutch Adjustment Slide the dust cover at the clutch cable upper end out of place Loosen the knurled locknut at the clutch lever Turn the adjuster so that the clutch lever will have 10 20mm of play NOTE O Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement Tighten the locknut If it cannot be done use the nuts A at the middle of cable so that clutch lever has 10 20mm of play After the adjustment start the engine and check that the clutch does not slip and that it releases properly http mototh com 5 6 ENGINE RIGHT SIDE LEFT SIDE Clutch Cover Clutch Cover Removal Drain the engine oil Remove the clutch cable bracket bolts A and then the cable lower
74. Remove the cap bolt A washer B and spring C Remove the mounting bolts D and take off the chain tensioner Installation Notes Installation is the reverse of removal Unlock the ratchet stopper A and push the rod B into the tensioner body C Check the O ring in the tensioner body for damage l f the O ring is damaged replace it Torque Camshaft Chain Tensioner Mounting Bolts 9 8 N m 1 0 kg m 87 in lb Chain Tension Spring Removal Unscrew the tension spring bolt B and take out the chain tension spring Chain Tension Spring Installation Replace the O ring A with a new one if it is damaged Insert the tension spring B in the chain guide protrusion C and install the chain tension spring bolt Torque Chain Tension Spring Bolt 15 N m 1 5 kg m 11 0 ft lb http mototh com ENGINE TOP END 4 9 Camshaft Camshaft Chain Camshaft Removal Remove Cylinder Head Cover Chain Tension Spring Camshaft Chain Tensioner Remove the camshafts cap bolt A and take off the cap B Remove the camshafts CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turning the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and sprocket Camshaft Installation Notes Including Camshaft Chain Timing Procedure Apply engine oil to all cam parts If the cams
75. This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substi tute tools may adversely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your JET SKI watercraft Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non sched
76. USPENSION Rear Suspension Uni Trak Rear Shock Absorber The rear suspension system of this motorcycle is Uni trak It consists of a rear shock absorber swingarm tie rod and rocker arm To suit to various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one KLX250D Also the damping force can be adjusted easily KLX250D so changing oil viscosity is unnecessary Rebound Damping Adjustment KLX250D T u r n the rebound damping adjuster A on the rear shock absorber lower end with the blade of a screwdriver until you feel a click l f the damper setting feels too soft or too stiff adjust it in accordance with the following table Rebound Damping Adjuster Setting Standard 9 clicks A Seated position adjuster turned fully clockwise Compression Damping Adjustment KLX250D T u r n the compression damping adjuster A on the gas reservoir with the blade of a screwdriver until you feel a click l f the damper setting feels too soft or too stiff adjust it in accordance with the following table Compression Damping Adjuster Setting Standard 14 clicks A Seated position adjuster turned fully clockwise http mototh com Spring Preload Adjustment KLX250D Remove the rear shock absorber see Rear Shock Absorber Removal Clean the threaded portion on the upper end of the rear shock absorber Hold the lower end of the rear
77. ace them Check the shift arm D for distortion l f the shift arm is damaged in any way replace the shift mechanism Check that the return spring pin A is not loose l f it is loose unscrew it apply a non permanent locking agent to the threads and torque it Torque Return Spring Pin 37 N m 3 8 kg m 27 0 ft lb Check the gear set lever and its spring for cracks or distortion l f the lever or spring is damaged in any way replace them http mototh com ENGINE LUBRICATION SYSTEM 6 Engine Lubrication System Table of Contents Exploded View 6 2 Specifications 6 3 Engine Oil Flow Chart 6 4 Engine Oil and Oil Filter 6 5 Oil Level Inspection 6 5 Oil and or Oil Filter Change 6 5 Oil Filter Removal 6 6 Oil Filter Installation Notes 6 6 Oil Pump and Relief Valve 6 7 Relief Valve Removal 6 7 Relief Valve Installation Notes 6 7 Oil Pump Removal 6 7 Oil Pump Installation Notes 6 7 Oil Pump Disassembly 6 7 Oil Pump Assembly Notes 6 8 Oil Pump Drive Gear Removal 6 8 Oil Pump Drive Gear Installation 6 8 Oil Pressure Measurement 6 8 When the engine is cold 6 8 When the engine is warmed up 6 9 Oil Pump Inspection 6 10 Relief Valve Inspection 6 10 Oil Screen 6 11 Removal 6 11 Installation Note 6 11 Cleaning and Inspection 6 11 Oil Pipe 6 12 Main Oil Pipe Removal 6 12 Main Oil Pipe Installation Notes 6 12 http mototh com 6 2 ENGIIME LUBRICATION SYSTEM Exploded View
78. ad nut lightly Settle the bearings in place as follows OTighten the stem locknut to 39 N m 4 0 kg m 29 ft lb of torque To tighten the steering stem locknut to the specified torque hook the wrench on the stem locknut and pull the wrench at the hole by 22 2 kg force in the direction shown http mototh com STEERING 13 7 Special Tool Steering Stem Nut Wrench 57001 1100 A O Check that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged O Again back out the stem locknut a fraction of a turn until it turns lightly OTurn the stem locknut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Locknut 3 9 N m 0 4 kg m 35 in lb Install the front fork see the Suspension chapter NOTE O Tighten the fork upper clamp bolts first next the stem head bolt last the fork lower clamp bolt Torque Steering Stem Head Nut 44 N m 4 5 kg m 33 ft lb Front Fork Upper Clamp Bolt 20 N m 2 0 kg m 14 5 ft lb Front Fork Lower Clamp Bolt 20 N m 2 0 kg m 14 5 ft lb Install the parts removed see the appropriate chapter AWARNING Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see the General Information chapter Check and adjust Steering Front Brake Clutch Cable Throttle Cable http mototh com 13 8 STEER
79. aged gasket C or O ring A l f the fuel tap leaks or allows fuel to flow when it is at OFF position replace the damaged gasket or O ring FUEL SYSTEM 2 15 http mototh com COOLING SYSTEM 3 1 Cooling System Table of Contents Exploded View 3 2 Specifications 3 4 Cooling System 3 5 Coolant 3 6 Coolant Inspection 3 6 Coolant Deterioration 3 6 Coolant Level 3 6 Coolant Change 3 7 Coolant Draining 3 7 Coolant Filling 3 7 Air Bleeding 3 8 Coolant Leak Inspection 3 9 Cooling System Pressure Testing 3 9 Cooling System Flushing 3 10 Water Pump 3 11 Water Pump Cover Removal 3 11 Water Pump Cover Installation Notes 3 11 Impeller Removal 3 11 Impeller Installation 3 11 Impeller Assembly Notes 3 11 Impeller Inspection 3 12 Mechanical Seal Oil Seal Removal 3 12 Mechanical Seal Oil Seal Installation 3 12 Mechanical Seal Inspection 3 13 Radiator 3 14 Radiator Removal 3 14 Radiator Installation 3 14 Radiator Inspection 3 14 Radiator Cap Inspection 3 14 Filler Neck Inspection 3 15 Water Hose Breather Hose Air Vent Hose Inspection 3 15 Water Hoses Breather Hose Air Vent Hose Installation Notes 3 15 Radiator Fan KLX250E 3 16 Removal 3 16 Installation Notes 3 16 Thermostat KLX250E 3 17 Removal 3 17 Installation Note 3 17 Inspection 3 17 Thermostatic Fan Switch Water Temperature Sensor KLX250E 3 18 Thermostatic Fan Switch Removal 3 18 Thermostatic Fan Switch Insta
80. ake out the tie rods C Tie Rod Installation Notes Apply plenty of molybdenum disulfide grease to the inside of the needle bearings and oil seals Torque the tie rod front and rear mounting nuts Torque Tie Rod Mounting Nuts 81 N m 8 3 kg m 60 ft lb Rocker Arm Removal Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 Loosen the swingarm pivot shaft nut C Remove the tie rod front mounting bolt A CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing Remove the rear shock absorber lower mounting bolt B Remove the rocker arm pivot shaft nut Remove the rocker arm pivot shaft C Remove the rocker arm D Rocker Arm Installation Notes Apply plenty of molybdenum disulfide grease to the inside of the rocker arm hole outside of the sleeve and needle bearing Torque the following Torque Rocker Arm Pivot Shaft Nut 98 N m 10 0 kg m 72 ft lb Rear Shock Absorber Mounting Bolt 39 N m 4 0 kg m 29 ft lb Tie Rod Mounting Nut 81 N m 8 3 kg m 60 ft lb Swingarm Pivot Shaft Nut 88 N m 9 0 kg m 65 ft lb http mototh com SUSPENSION 12 27 Uni trak Maintenance Check the uni trak component parts for wear periodically or whenever excessive play is suspected Using the jack under the frame raise the rear wheel off the g
81. aliper Prepare a container for brake fluid and perform the work above it Remove the pads and spring see Pad Removal Pump the brake lever or pedal to remove the caliper piston s Remove the dust seal s and fluid seal s Remove the bleed valve and rubber cap Assembly Notes Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol Tighten the bleed valve Torque Caliper Bleed Valve 7 8 N m 0 8 kg m 69 in lb Replace the fluid seals which are removed with new ones O Apply brake fluid to the fluid seals A and install them into the cylinders by hand Replace the dust seals with new ones if they are damaged Apply brake fluid to the dust seals B and install them into the cylinders by hand Apply brake fluid to the outside of the pistons C and push them into each cylinder by hand http mototh com Replace the shaft rubber friction boot A and dust cover B if they are damaged Apply a thin coat of PBC Ploy Butyl Cuprysil grease to the caliper holder shafts C and holder holes PBC is a special high temperature water resistant grease Install the anti rattle spring A in the caliper as shown Install the pads see Pad Installation Notes Wipe up any spilled brake fluid on the caliper with damp cloth BRAKES 11 11 http mototh com 11 12 BRAKES Brake Pads Re
82. all height 1210 mm Wheelbase 1440 mm Road clearance 300 mm Seat height 890 mm Dry weight 120 kg Curb weight Front 62 kg Rear 72 kg Fuel tank capacity 8 L Performance Minimum turning rad ius 2 4 m Engine Type 4 stroke DOHC 1 cylinder Cooling system Liquid cooled Bore and stroke 72 0x61 2 mm Displacement 249 mL Compression ratio 11 0 1 Maximum horsepow er 18 4 kW 25 PS 8 000 r min rpm W 9 5 kW 13 PS 5 000 r min rpm Maximum Torque 22 5 N m 2 3 kg m 16 6 ft lb 7 500 r min rpm W 18 5 N m 1 9 kg m 13 7 ft lb 4 000 r min rpm Carburetion system Carburetor KEIHIN CVK34 Starting system Ignition system Timing advance Ignition timing Spark plug Cylinder numbering method Firing order Valve timing Inlet Open Close Duration Open Close Duration Exhaust Lubrication system Engine oil Grade Viscosity Capacity Primary kick CDI Electronically advanced 5 BTDC 1 300 r min rpm to 35 BTDC 5 000 r min rpm NGKCR8E NDU24ESR N 22 BTDC 62 ABDC 264 61 BBDC 19 ATDC 260 Forced lubrication wet sump SE SF or SG class SAE10W 40 10W 50 20W 40 or 20W 50 1 5 L http mototh com 17 4 SUPPLEMEMT FOR 1994 MODEL Items KLX250 G1 G2 Drive Train Primary reduction system Type Gear Reduction ratio 2 863 63 22 Clutch type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear ratios
83. ameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Standard Inlet 28 4 28 6 Exhaust 24 4 24 6 O Measure the seat width E of the portion where there is no build up carbon white portion on the valve seat with a vernier caliper l f the width is too side too narrow or uneven repair the seat see Seat Repair Valve Seating Surface Width Standard Inlet Exhaust 0 5 1 0 mm Seat Repair Repair the valve seat with the valve seat cutters Special Tools Valve Seat Cutter Holder 04 5 57001 1330 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 45 027 5 57001 1114 Valve Seat Cutter 32 Valve Seat Cutter 60 Valve Seat Cutter 32 Valve Seat Cutter 45 Valve Seat Cutter 60 l f the manufacturer s instructions are not available use the following procedure 028 57001 1119 030 57001 1123 030 57001 1120 024 5 57001 1113 025 57001 1328 http mototh com ENGINE TOP END 4 21 Seat Cutter Operating Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purpose than seat repair 2 Do not drop or shock the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil M O T E ODo not use a w
84. apping on a bolt could damage the bolt sleeve and bearing Remove the swingarm pivot shaft nut Pull out the swingarm pivot shaft B and remove the swingarm C Separate the chain guide and chain slipper from the swingarm Installation Notes Apply plenty of molybdenum disulfide grease to the inside of the needle bearings and sleeves Torque the following Torque Swingarm Pivot Shaft Nut 88 N m 9 0 kg m 65 ft lb Tie Rod Mounting Nut 81 N m 8 3 kg m 60 ft lb Refer to the Wheels Tires Final Drive and Brakes chapters for wheel installation Scrapping AWARNING Since the rear shock absorber contains nitrogen gas do not incinerate the rear shock absorber Before a rear shock absorber is scrapped release the nitrogen gas completely Do not point the valve A toward your face or body Swingarm Removal Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter Remove the brake pedal Remove the tie rod rear mounting bolt A http mototh com 12 26 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 Remove the tie rod front mounting bolt A CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing Remove the tie rod rear mounting bolt B and then t
85. apply a little coolant to the sliding surface to give the mechanical seal initial lubrication Apply coolant to the surface A of the rubber seal B and sealing seat C and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole http mototh com 3 12 COOLING SYSTEM Impeller Inspection Visually check the impeller A l f the surface is corroded or if the blades B are damaged replace the impeller Mechanical Seal Oil Seal Removal Remove Impeller Right Engine Cover see Right Engine Cover Removal in the Engine Right Side Left Side chapter Insert a bar A into the water pump shaft hole from the outside of the right engine cover and remove the ball bearing B and the oil seal C by tapping evenly around the bearing inner race and seal lips Press out the mechanical seal A from the inside of the right engine cover with a bearing driver set Special Tool Bearing Driver Set 57001 1129 Mechanical Seal Oil Seal Installation CAUTION If the mechanical seal oil seal or ball bearing is removed replace all of them with new ones at the same time Oo not obstruct the drainage outlet passage with liquid gasket or the oil seal If it is obstructed the coolant may be forced through the oil seal and mix with the engine oil http mototh com COOLING SYSTEM 3 13 Apply plenty of high temperature grease to the oil sea
86. ar Sprocket Standard 237 54 238 04 mm 49T KLX250D 202 32 202 82 42T KLX250E Service Limit 237 2 mm KLX250D 202 0 mm KLX250E NOTE O f a sprocket requires replacement the chain is probably worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Inspection Elevate the rear wheel so that it will turn freely and set a dial gauge against the rear sprocket near the teeth as shown Rotate the rear wheel The difference between the highest and lowest dial gauge readings is the amount of runout warp l f the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard Under 0 4 mm Service Limit 0 5 mm FINAL DRIVE 10 9 http mototh com Brakes Table of Contents Exploded View 11 2 Specifications 11 4 Brake Lever Brake Pedal 11 5 Lever Play Adjustment 11 5 Pedal Position Pedal Play Adjustment 11 5 Level Inspection 11 6 Change 11 6 Bleeding the Brake Line 11 7 Caliper 11 9 Front Caliper Removal 11 9 Rear Caliper Removal 11 9 Installation Notes 11 9 Disassembly 11 10 Assembly Notes 11 10 Brake Pads 11 12 Removal 11 12 Installation Notes 11 12 Inspection 11 12 Master Cylinder 11 13 Front Master Cylinder Removal 11 13 Front Master Cylinder Installation Notes 11 13 Rear Master Cylinder Removal 11 13 Rear Master Cylinder Installation Notes 11 14 Front Master Cylinder Disassembly 11 14 Rear Master Cylinder Disassembly
87. attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Inspection Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 Spin the wheel lightly and check for roughness of binding l f roughness or binding is found replace or lubricate the hub bearings Visually inspect the front and rear axles for damage l f axle is damaged or bent replace it Spoke Inspection Check that all the spokes are tightened evenly l f spoke tightness is uneven or loose torque the spoke nipples evenly Torque Spoke Nipples 1 5 N m 0 15 kg m 13 in lb Check the rim runout AWARNING If any spoke breaks it should be replaced immediately A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break http mototh com Rim Inspection Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 Inspect the rim for small cracks dents bending or warping l f there is any damage to the rim it must be replaced Set a dial gauge B against the side of the rim A and rotate the rim to measure the axial runout C The difference between the highest and lowest dial readings
88. b T2 9 8 N m 1 0 kg m 87 in lb T3 12 N m 1 2 kg m 8 5 ft lb T4 15 N m 1 5 kg m 11 0 ft lb T5 20 N m 2 0 kg m 14 5 ft lb T6 46 N m 4 7 kg m 34 ft lb T7 25 N m 2 5 kg m 18 0 ft lb T8 2 5 N m 0 25 kg m 22 in lb http mototh com ENGINE TOP END 4 3 http mototh com 4 4 ENGINE TOP END Specifications Item Standard Service Limit Camshaft Cam height Exhaust 36 25 36 35 mm 36 15 mm Inlet 36 25 36 35 mm 36 15 mm Camshaft bearing oil clearance 0 020 0 062 mm 0 15 mm Camshaft journal diameter 22 959 22 980 mm 22 93 mm Camshaft bearing inside diameter 23 000 23 021 mm 23 08 mm Camshaft runout TIR 0 02 mm or less TIR 0 1 mm Camshaft chain 20 link length 127 0 127 4 mm 128 9 mm Cylinder Head Cylinder Compression Usable range 440 735 kPa 4 5 7 5 kg cm2 64 127 psi Cylinder head warp 0 05 mm Valves Valve clearance Exhaust 0 15 0 24 mm Inlet 0 10 0 19 mm Valve head thickness Exhaust 0 8 mm 0 5 mm Inlet 0 5 mm 0 25 mm Valve stem bend TIR 0 01 mm or less TIR 0 05 mm Valve stem diameter Exhaust 4 455 4 470 mm 4 44 mm Inlet 6 965 4 475 mm 4 490 mm Valve guide inside diameter Exhaust 4 500 4 512 mm 4 58 mm Inlet 4 500 4 512 mm 4 58 mm Valve valve guide clearance wobble method Exhaust 0 12 0 2 2 mm 0 48 mm Inlet 0 04 0 13 mm 0 38 mm Valve seat cutting angle 45 32 60
89. battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loosened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medical attention if severe VTI Interchangeably with Ordinary Battery A maintenance free battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a maintenance free battery only on a motorcycle which was originally equipped with a maintenance free battery Be careful if a maintenance free battery is installed on a motorcycle which had an ordinary battery as original equipment the maintenance free batterys life will be shortened http mototh com SUPPLEMENT FOR 1994 MODEL 17 11 Fuel System Specifications KLX250G Item Standard Throttle Grip Free Play 2 3 mm Carburetor Make type KEIHIN CVK34 Pilot screw turns o ut 1 1 2 W 1 1 4 Service fuel level 1 5mm above 0 5mm below the float bowl mating surface Float height 17 0 2 mm Main jet 132 Main air jet 50 Jet needle mark N1RX W NIRV Jet needle clip posi tion Slow jet 35 Slow air jet 145 Starter jet 40 Air Cleaner Element Oil 2 stroke racing oil or high quality form air filter oil
90. battery eliminates the need for a gas exhaust tube 7 Strong charge discharge characteristics It can amply withstand deep charge discharge cycles HI Principle of Sealing Structure A lead acid battery operates under the following chemical reaction Discharge Pb02 2H2S04 Pb PbSCU 2H2O PbSCk Lead peroxide Sulfuric acid Spongy lead Charge Lead sulfate water Lead sulfate Positive active Electrolyte Negative active Positive active Electrolyte Negative active material material material material Normally in an ordinary lead acid battery when it comes to an end of a charge where the lead sulfate being a discharge product returns to lead peroxide and spongy lead the charge current flowing thereafter is used exclusively to decompose electrolytically water from the electrolyte thus resulting in generation of hydrogen gas from the negative plate and oxygen gas from the positive plate The gases so generated are released out of the battery causing the amount of electrolyte decreased to require occasional water replenishment http mototh com 17 8 SUPPLEMENT FOR 1994 MODEL A maintenance free battery however is so designed that when it is overcharged even if the positive plate is fully charged the negative plate remains not fully turned to spongy lead Therefore even when the positive plate is overcharged generating oxygen gas the negative plate is no fully charged hence generat
91. cam spring is damaged deformed missing or weights do not move smoothly l f cylinder compression is lower than the usable range check the following 1 Gas leakage around the cylinder head replace the damaged gasket and check the cylinder head warp 2 Condition of the valve seating 3 Valve clearance 4 Piston cylinder clearance piston seizure 5 Piston ring piston ring groove 6 Compression release weights do not move smoothly Removal Remove Fairings Coolant drain Exhaust Pipe Radiator Covers Seat Fuel Tank Carburetor Water Hose Ignition Coil Cylinder Head Cover http mototh com ENGINE TOP END 4 13 Camshaft Chain Tensioner Camshafts Cylinder Head Bracket Oil Pipe Mounting Bolt loosen Oil Pipe Upper Banjo Bolt Remove the cylinder head bolts in the following order 1 6 mm Bolts A 2 8mm Allen Bolts B gt Remove the chain guide C Lift off the cylinder head toward the left side and remove the cylinder head gasket N O T E O Tap lightly up the cylinder head with a rubber mallet B to separate from the cylinder A CAUTION Be careful not to damage the radiator core Installation Notes T h e camshaft caps are machined together with the cylinder head so if a new cylinder head is installed use the caps that are supplied with the new head Apply a molybdenum disulfide grease to the cylinder head bolts 8 mm Allen seating surfaces and threads Tempora
92. can surface Set the oil level gauge stopper B so that its lower side shows the oil level distance specified NOTE O The gauge tube is graduated in 1 cm division O The gauge body is graduated in 10 mL division excluding the gauge tube of about 5 mL capacity With the fork fully compressed insert the gauge tube into the inner tube and position the stopper across the top of the outer tube Pull the handle slowly to draw out all excess oil Special Tool Fork Oil Level Gauge 57001 1290 A http mototh com Oil Level fully compressed without spring Standard 97 2 mm Install the parts removed Removal Remove the fork protectors Remove the caliper from the fork leg to be removed and rest the caliper on some kind of stand so that it does not dangle Remove the front wheel see Front Wheel Removal in the Wheels Tires chapter Loosen the upper and lower clamp fork bolts A With a twisting motion work the fork leg down and out NOTE O If the front fork is to be disassembled first loosen the upper clamp bolts and then loosen the top plug Installation Notes If the fork leg was disassembled check the fork oil level Route the cables and hose according to the Cable Wire and Hose Routing section in the General Information chapter Torque the following Torque Fork Upper Clamp Bolts 20 N m 2 0 kg m 14 5 ft lb Fork Lower Clamp Bolts 20 N m 2 0 kg m 14 5 f
93. cessary CA California Model US U S Model http mototh com SUPPLEMENT FOR 1994 MODEL 17 7 Technical Information Maintenance Free Battery A maintenance free battery is installed in this model The maintenance free battery is a sealed type and so cannot be performed the electrolyte level check and toppinq up I Construction II Main Features 1 Maintenance free It is not necessary to check the electrolyte level and top off the electrolyte 2 No electrolyte leakage As the electrolyte is retained firmly in the special separators there is no free electrolyte in the battery 3 Instant activation system It can be used instantly after filling only the electrolyte without initial charge 4 One push motion electrolyte filling It is possible to fill the electrolyte by easy one push motion 5 Safety construction If the battery internal pressure rises abnormally high the safety valve opens to release the gas inside the battery to restore the normal pressure and prevent the battery from rupturing After restoring the normal pressure the safety valve closes and the battery is sealed again Moreover a ceramic filter is disposed on top of the safety valve under the lid to remove risk of ignition or explosion caused by fire from outside 6 Compact and high performance No presence of free electrolyte allows the battery made lower in height thus resulting in enhanced volume efficiency Moreover gas being absorbed inside the
94. ck the brake for weak braking power and brake drag see the Brakes chapter http mototh com 10 8 FINAL DRIVE Sprocket Engine Sprocket Removal Remove Engine Sprocket Cover Circlip A Remove the engine sprocket B Engine Sprocket Installation Notes Installation is the reverse of removal Replace the circlip with a new one Rear Sprocket Removal Remove the rear wheel see rear wheel removal in Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Unscrew the rear sprocket nuts and remove the rear sprocket Rear Sprocket Installation Notes Installation is the reverse of removal Install the rear sprocket A so that the marked side B faces out Tighten the rear sprocket nuts Torque Rear Sprocket Nuts 29 N m 3 0 kg m 22 ft lb Sprocket Wear Inspection Visually inspect the engine and rear sprocket teeth for wear and damage l f they are worn as illustrated or damaged replace the sprocket Measure the diameter of the sprocket at the base of the teeth l f the sprocket is worn down to less than the service limit replace the sprocket Sprocket Diameter Engine Sprocket Standard 60 69 61 19 mm 14T KLX250D 60 98 61 18mm 14T KLX250E Service Limit 60 3 mm KLX250D 60 3 mm KLX250E http mototh com Re
95. d with new ones Spin it by hand to check its condition l f it is noisy does not spin smoothly or has any rough spots it must be replaced Examine the bearing seal for tears or leakage l f the seal is torn or is leaking replace the bearing http mototh com WHEELS TIRES 9 11 Speedometer Gear Housing Disassembly and Assembly NOTE Olt is recommended that the assembly be replaced rather than attempting to repair the components Install the speedometer gear housing so that it fits in the speedometer gear drive notches see Front Wheel Installation Notes Lubrication Clean and grease A the speedometer gear housing B in accord ance with the Periodic Maintenance Chart http mototh com FINAL DRIVE 10 1 Final Drive Table of Contents Exploded View 10 2 Specifications 10 3 Drive Chain 10 4 Drive Chain Slack Inspection 10 4 Drive Chain Slack Adjustment 10 4 Wheel Alignment Inspection 10 5 Wheel Alignment Adjustment 10 6 Drive Chain Wear Inspection 10 6 Drive Chain Lubrication 10 6 Drive Chain Removal 10 7 Drive Chain Installation Notes 10 7 Sprocket 10 8 Engine Sprocket Removal 10 8 Engine Sprocket Installation Notes 10 8 Rear Sprocket Removal 10 8 Rear Sprocket Installation Notes 10 8 Sprocket Wear Inspection 10 8 Rear Sprocket Warp Inspection 10 9 http mototh com 10 2 FINAL DRIVE Exploded View KLX250D E G Apply Grease T1 29 N m 3 0 kg m 22 fl lb
96. de down 460 5 mm Service limit 451 mm Conventional 506 mm Service limit 496 mm Rear Shock Absorber Rebound damper set KLX250D 9th click from the first click of the fully clockwise position Compression damper set KLX250D 14th click from the first click of the fully clockwise position Spring setting position KLX250D Standard adjusting nut position 115 5 mm 4 55 in Nut adjusting range 106 128 mm 4 16 5 04 in KLX250E 2nd step from the stronger position Usable range 5 steps Gas pressure 980 kPa 10 kg cm2 142 psi Non adjustable Oil type KLX250D SAE5W or Bel Ray SE2 40 Oil capacity KLX250D 305 mL Spring free length KLX250D 240 5 mm Service limit 236 mm Rocker Arm Sleeve outside diameter Long 21 987 22 000 mm Service limit 21 85 mm Short 19 000 19 120 mm Service limit 18 88 mm Bolt runout Under 0 1 mm Service limit 0 2 mm Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1057 Hook Wrench 57001 1101 Bearing Driver Set 57001 1129 Fork Outer Tube Weight 57001 1218 Jack 57001 1238 Fork Spring Holder 57001 1286 Fork Cylinder Holder 57001 1287 Fork Oil Level Gauge 57001 1290 Fork Piston Rod Puller M10 x 1 0 57001 1298 Hexagon Wrench Hex 29 57001 1335 Fork Oil Seal Driver lt P43 57001 1340 http mototh com SUSPENSION 12 5 Front Fork Conventional Type Air Pressure Adjustment The standard air pressure i
97. dition of components or accessories that result in the vehicle exceeding the standards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover Modifications to the muffler s or air intake system by cutting drilling or other means if such modifications result in increased noise levels http mototh com Quick Reference Guide This quick reference guide will assi
98. e After adjustment tighten the locknut Pedal Position Pedal Play Adjustment The brake pedal position and pedal play should not be adjusted There is no pedal position adjustment device installed NOTE O Usually it is not necessary to adjust the push rod length but adjust it when the rear master cylinder A is disassembled O When the brake pedal is in its rest position measure the length B indicated in the figure Length A Standard 52 mm If the length B is not within the specified length loosen the locknuts C and adjust the length Tighten the locknuts Torque Rear Brake Push Rod Locknut 17 N m 1 75 kg m 12 7 ft lb AWARNING When working with the disc brake observe the precautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasolin
99. e engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up immediately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE http mototh com 11 6 BRAKES Level Inspection In accordance with the Periodic Maintenance Chart inspect that the brake fluid level in the front brake reservoir A is more than half full NOTE O Hold the reservoir horizontal when checking brake fluid level Check the brake fluid level in the front brake reservoir A is more than half full Check that the brake fluid level in the rear brake reservoir A is between the upper B and the lower C level lines if the fluid level is lower than the lower level line fill the reservoir to the upper level line on the reservoir AWARNING Change the brake fluid in the brake line completely if the brake fluid must be
100. e a meter illumination bulb rated for other than the voltage or wattage specified in the wiring diagram as the meter panel could be warped by excessive heat radiated from the bulb OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system operation O Measure coil and winding resistance when the part is cold at room temperature O Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Light green W White DG Dark green 0 Orange Y Yellow O Electrical Connectors A Female Connectors B Male Connectors http mototh com ELECTRICAL SYSTEM 15 7 Electrical Wiring Inspection Visually inspect the wiring for signs of burning fraying etc l f any wiring is poor replace the damaged wiring Pull each connector A apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity O Use the wiring diagram to find the ends of the lead which is suspec
101. e engine is warm hot engine oil will drain through the oil passage take care against burns Torque Banjo Bolts lt J gt 10 9 8 N m 1 0 kg m 87 in lb 12 20 N m 2 0 kg m 14 5 ft lb If the banjo bolt is removed while the engine is warm hot engine oil will drain through the oil passage take care against burns Torque Banjo Bolts lt J gt 10 9 8 N m 1 0 kg m 87 in lb 12 20 N m 2 0 kg m 14 5 tt lb http mototh com ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents Exploded View 7 2 Specification 7 3 Engine Removal Installation 7 3 Removal 7 3 Installation Notes 7 3 http mototh com 7 2 ENGINE REMOVAL INSTALLATION Exploded View KLX250D E T1 29 N m 3 0 kg m 22 ft lb T2 44 N m 4 5 kg m 33 ft lb T3 88 N m 9 0 kg m 65 ft lb http mototh com ENGINE REMOVAL INSTALLATION 7 3 Specification Special Tool Jack 57001 1238 Engine Removal Installation Removal Remove or disconnect see appropriate chapter Engine Oil drain Coolant drain Seat Side Covers Fuel Tank Exhaust Pipe Carburetor Ignition Coil Water Hoses Radiators Clutch Cable Lower End Cylinder Head Bracket Engine Breather Hose Lower End Regulator Engine Sprocket Cover Engine Sprocket Shift Pedal Right Footpeg Rear Brake Master Cylinder Joint Pin and Cotter Pin Brake Pedal and Spring Magneto Lead Connectors disconnect Place the jack D stand under the frame to
102. e first l f the reading exceeds the service limit replace the guide NOTE O The reading is not actual valve to valve guide clearance because the measuring point is above the guide Valve to Valve Guide Clearance Wobble Method Standard Service Limit Inlet 0 04 0 13 mm 0 38 mm Exhaust 0 12 0 22 mm 0 48 mm ENGINE TOP END 4 23 http mototh com 4 24 ENGINE TOP END Valve Seat Repair http mototh com ENGINE TOP END 4 25 Cylinder Piston Cylinder Removal Remove the cylinder head see Cylinder Head Removal Pull off the water pump hose A Lift off the cylinder A and remove the cylinder base gasket NOTE O Tap lightly around the base of the cylinder with a rubber mallet B Cylinder Installation Notes Replace the cylinder base gasket with a new one A p p l y engine oil to the piston surface piston rings and cylinder bore Install the cylinder Set the chain guide into the crankcase concavity securely Piston Removal Remove the cylinder Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase Remove one of the piston pin snap rings with needle nose pliers Remove the piston by pushing the piston pin out the side from which the snap ring was removed Use a piston pin puller assembly A and adapter B if the pin is tight Special Tool Piston Pin Puller Assembly 57001 910 gt Remo
103. e outside of each piston B l f the master cylinder or piston shows any damage replace them Inspect the primary C and secondary D cups l f a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups l f fluid leakage is noted at the brake lever the piston assembly should be replaced to renew the cups Check the dust covers E for damage If they are damaged replace them Check that the relief F and supply G ports are not plugged l f the small relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Check the piston return springs H for any damage l f the spring is damaged replace it BRAKES 11 15 http mototh com 11 16 BRAKES Brake Disc Inspection Visually inspect the disc l f it is scratched or damaged replace the disc Measure the thickness of each disc at the point where it has worn the most Replace the disc if it has worn past the service limit Thickness KLX250D Standard Service Limit KLX250E Standard Service Limit Front 2 85 3 15 mm 2 5 mm Front 3 35 3 65 mm 2 8 mm Rear 4 35 4 65 mm 3 8 mm Rear 4 35 4 65 mm 3 8 mm Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 Set up a dial gauge against the disc A as illustrated O For t
104. e reservoir cap check that there is plenty of fluid in the reservoir With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir O Bleed the air completely from the master cylinder by this operation Install the reservoir cap Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container Bleed the brake line and the caliper as follows O Repeat this operation until no more air can be seen coming out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close the bleed valve while holding the brake applied B 3 Release the brake C BRAKES 11 7 http mototh com 11 8 BRAKES NOTE O The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs almost out any time during bleeding operation the operation must be done over again from the beginning since air will have entered the line O Tap the brake hose lightly from the caliper to the reservoir for easier bleeding Remove the clear plastic hose Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 8 kg m 69 in lb Check the fluid level After bleeding is done check the
105. e type Front Rear Tubular semi double cradle 26 5 107 mm Tube D752F AS US K490 80 100 21 51 M Tube D752 AS US K695 100 100 18 59M Telescopic fork AS US Telescopic fork upside down 290 mm AS US 285 mm Swingarm uni trak 280 mm Single disc Single disc Electrical Equipment Headlight Type Bulb Taillight Alternator Type Rated output Semi sealed beam 12 V 30 W 12 V 1 0 W Three phase AC Specification subject to change without notice and may not apply to every country AS Australia Model US U S Model http mototh com 1 8 GENERAL INFORMATION Items KLX250 E1 E2 E3 Dimensions Overall length 2135 mm FG NR 2220 mm IT 2170 mm Overall width 870 mm Overall height 1210 mm Wheel base 1440 mm Road clearance 300 mm Seat height 890 mm Dry weight 115 kg Curb weight Front 60 kg Rear 69 kg Fuel tank capacity 8 L Performance Minimum turning radius 2 4 m Engine Type 4 stroke DOHC 1 cylinder Cooling system Liquid cooled Bore and stroke 72 0 x 61 2 mm Displacement 249 mL Compression ratio 11 0 1 Maximum horsepower 18 4 kW 25 PS 8000 r min rpm AR 9 5 kW 13 PS 5000 r min rpm Maximum torque 22 5 N m 2 3 kg m 16 6 ft lb 7500 r min rpm AR 18 5 N m 1 9 kg m 13 7 ft lb 4000 r min rpm Carburetion system Carburetor KEIHIN CVK34 Starting system Primary kick Ignition system CDI Timing advance El
106. eaner intake cap Remove the wing bolt A and take out the air cleaner element B Element Installation Notes Coat the element lip with a thick layer of all purpose grease A to assure a complete seal against the air cleaner element base Be sure the foam gasket is in place in the groove in the intake cap http mototh com FUEL SYSTEM 2 13 Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately O Since repeated cleaning opens the pores of the foam in the element replace it with a new one in accordance with the Periodic Mainte nance Chart Also if there is a break in the element material or any other damage to the element rep ace the element with a new one ikWARNING Clean the element in a well ventilated area and make sure that there are no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element Removetheaircleaner element and separate the element A from the element frame B Clean the element in a bath of a high flash point solvent Dry it with compressed air or by shaking it Check all the parts of the element for visible damage l f any of the part of the element is damaged replace it After cleaning sa
107. ect sequence facing the proper direction and that all circlips and washers are properly in place 1 2nd gear 30T plain side faces left A 2 6th gear 19T fork groove goes to the right side of the gear teeth B 3 3rd gear 27T dog recesses face left C 4 4th gear 25T dog recesses face right D 5 5th gear 21T fork groove goes to the left side of the gear teeth E 6 1 st gear 30T plain side faces right F Check each gear spins or slides freely on the transmission shaft without binding after assembly Shift Drum and Fork Installation Notes Apply a little engine oil to the shift fork fingers and fit the shift forks into the gear grooves Shift Fork Identification Drive shaft 3rd 4th gear shift fork A Fingers are shorter than those of the other two shift forks Output shaft 6th gear shift fork B guide pin goes to right side of the fingers Output shaft 5th gear shift fork C guide pin goes to center Tighten the shift drum bearing retaining bolts securely Torque Shift Drum Bearing Retaining Bolts 9 8 N m 1 0 kg m 87 in lb Fit the shift fork guide pins into the corresponding shift drum grooves Tighten the shift drum cam Allen bolt Torque Shift Drum Cam Allen Bolt 12 N m 1 2 kg m 8 5 ft lb Apply a little engine oil to the shift rod and slide it into the shift forks NOTE O Install the shift drum holder into the shift drum Shift Fork Bending Visually ins
108. ectronically advanced Ignition timing 5 BTDC 1300 r min rpm to 35 BTDC 5000 r min rpm Spark plug NGKCR8E NDU24ESR N Cylinder numbering method Firing order Valve timing Inlet Open 22 BTDC Close 62 ABDC Duration 264 Exhaust Open 61 BBDC Close 19 ATDC Duration 260 Lubrication system Forced lubrication wet sump Engine oil Grade SE or SF class Viscosity SAE10W 40 10W 50 20W 40 or 20W 50 Capacity 1 5 L http mototh com GENERAL INFORMATION 1 9 Items KLX250 E1 E2 E3 Drive Train Primary reduction system Type Gear Reduction ratio 2 863 63 22 Clutch type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear ratios 1st 3 000 30 10 2nd 2 000 30 15 3rd 1 500 27 18 4th 1 250 25 20 5th 1 050 21 20 6th 0 904 19 21 Final drive system Type Chain drive Reduction ratio 3 000 42 14 Overall drive ratio 7 772 Top gear Frame Type Tubular semi double cradle Caster rake angle 26 5 Trail 109 mm AS 107 mm Front tire Type Tube DUN LOP D603 Size 3 00 21 51 P Rear tire Type Tube DUNLOP D603 Size 4 60 18 63P Front suspension Type Telescopic fork AS Telescopic fork upside down Wheel travel 290 mm AS 285 mm Rear suspension Type Swingarm uni trak Wheel travel 280 mm Brake type Front Single disc Rear Single disc Electrical Equipme
109. ed View KLX250D E KLX250D KLX250E KLX250E KLX250D SS Apply sillicone sealant 1 Regulator Rectifier T1 2 Condenser T2 3 Ignition Coil T3 4 IC Igniter T4 14 N m 1 4 kg m 10 ft lb 120 N m 12 0 kg m 87 H lb 5 9 N m 0 6 kg m 52 in lb 2 5 N m 0 25 kg m 22 in lb http mototh com ELECTRICAL SYSTEM 15 3 KLX250D E KLX250D KLX250D http mototh com 15 4 ELECTRICAL SYSTEM KLX250D 1 Front Brake Switch 2 Engine Stop Switch 3 Lighting Switch 4 Side Stand Switch 5 Rear Brake Switch 6 Diode 7 Turn Signal Light Relay 8 head Light Relay http mototh com ELECTRICAL SYSTEM 15 5 Specifications Item Standard Service Limit Charging System KLX250E Alternator type Charging voltage regulator rectifier output voltage Alternator output voltage Charging coil resistance Regulator rectifier resistance Three phase AC 14 15V more than 34 V 4000 r min rpm 0 4 1 1 Q x 1Q in the text II iii II iii II iii Ignition System Pickup coil air gap Pickup coil resistance Ignition coil 3 needle arcing distance Primary winding resistance Secondary winding resistance Spark plug Spark plug gap Spark plug cap resistance Exciter coil resistance KLX250D CDI unit resistance 0 4 0 6 mm 180 280 n x 10 Q 7 mm or more 0 2Q 15 x l Q 6 3 kQ 1 5 x 1 kQ 0 7 0 8 mm 3 75 6 25 k Q x 1 kQ 100 190 Q x 10Q in the text II iii ii i i
110. ed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instructions or procedures which if not correctly followed could result in personal injury or loss of life This caution symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment http mototh com This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE o This note symbol indicates points of partic ular interest for more efficient and convenient operation Indicates a procedural step or work to be done o Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly http mototh com EMISSION CONTROL ll lFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems i
111. eel rails must be about 30 40 of angle from the opening of the top ring to either side http mototh com ENGINE TOP END 4 27 Piston Ring Piston Ring Groove Wear Check for uneven groove wear by inspecting the ring seating T h e rings should fit perfectly parallel to the groove surfaces If not the piston must be replaced With the piston rings in their grooves make several measurements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Service Limit Top 0 03 0 07 mm 0 17 mm Second 0 03 0 07 mm 0 17 mm Piston Ring End Gap Place the piston ring A inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Service Limit Top 0 20 0 35 mm 0 7 mm Second 0 20 0 35 mm 0 7 mm Cylinder Inside Diameter Since there is a difference in cylinder wear in different directions take a side to side and a front to back measurement at each of the 3 locations total of 6 measurements shown in the figure l f any of the cylinder inside diameter measurements exceeds the service limit the cylinder will have to be bored to oversize and then honed Cylinder Inside Diameter Standard 72 000 72 012 mm Service Limit 72 1 mm A 10 mm B 60 mm C
112. enance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are exceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the standards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air b
113. ensioner see this chapter Cam Chain Tension Spring see this chapter Torque Camshaft Cap Bolt 12 N m 1 2 kg m 8 5 ft lb CAUTION After this procedure if any resistance is felt while turning over the crankshaft stop immediately and check the camshaft chain timing Valves will be bent if the timing is not properly set Camshaft and Sprocket Assembly Notes The inlet and exhaust sprockets are identical Install the sprockets so that the marked side faces outwards Apply a non permanent locking agent to the camshaft sprocket bolts and tighten them Torque Camshaft Sprocket Bolts 12 N m 1 2 kg m 8 5 ft lb If a new camshaft is to be used apply a thin coat of molybdenum disulfide grease to the cam surfaces Camshaft Bearing Oil Clearance Inspection Measure each clearance between the camshaft journal and camshaft cap using plastigage press gauge A OTighten the camshaft cap bolts Torque Camshaft Cap Bolts 12 N m 1 2 kg m 8 5 ft lb N O T E ODo not turn the camshaft when the plastigauge is between the journal and camshaft cap l f the clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Bearing Oil Clearance Standard 0 020 0 062 mm Service Limit 0 15 mm l f the camshaft journal diameter is less than the service limit see Specifications replace the camshaft with a new one and measure the clearance again l f the clea
114. ent Point the valve A away from you Slowly release nitrogen gas pressure by pushing down the valve core with a screwdriver AWARNING Do not point the valve toward your face or body when releasing the nitrogen gas pressure An oil mist is often released with the nitrogen Always release the nitrogen gas pressure before disassembling the rear shock absorber to prevent explosive separation of parts Adjust the gas reservoir damping adjuster to the softest position Remove the air bleeder bolt A and pump the rear shock to drain the oil out of the rear shock absorber body Install the air bleeder bolt Using a suitable tool A and press B push the reservoir cap in 10 mm Remove the circlip A from the gas reservoir Install a steel tire valve cap A on the gas reservoir valve and pull the gas reservoir cap out of the gas reservoir using pliers OThe bladder B comes out with the gas reservoir cap http mototh com 12 22 SUSPENSION Pry or tap B at the gaps A in the stop with suitable tools to free the stop form the rear shock body Slide the stop up to the top of the push rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly 10 mm down Remove the circlip A Lightly move the push rod back and forth and pull out the push rod assembly Pour the oil out of the rear shock body Assembly Notes KLX250D Adjust the gas res
115. er part of the rear shock body If oil comes out of the air bleeder bolt hole let it overflow until it stops l f oil does not come out of the air bleeder bolt hole add the specified oil through the air bleeder bolt hole until it overflows that is until all the remaining air is forced out Install the air bleeder bolt securely Fully extend the push rod assembly Inject nitrogen gas to a pressure of 50 kPa 0 5 kg cm2 7 psi through the valve on the gas reservoir Check the rear shock body and gas reservoir for oil and gas leaks l f there are no leaks inject the nitrogen gas up to 980 kPa 10 kg cm2 142 psi pressure WARNING Pressurize the gas reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire hazard or substandard performance High pressure gas is dangerous Have a qualified mechanic perform this procedure Install the spring and spring guide Adjust spring preload Reinstall the rear shock absorber Install the parts removed Spring Tension KLX250D Since a spring becomes shorter as it weakens check its free length to determine the condition l f the springs is shorter than the service limit it must be replaced Rear Shock Absorber Spring Length Standard 240 5 mm Service Limit 236 mm http mototh com SUSPENSION 12 25 CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or t
116. er to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substi tute tools may adversely affect safe operation For the duration of the warranty period especially we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your Motorcycle Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled mainte nance Use proper tools and genuine Kawasaki Motorcy cle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcy cles are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don t take shortcuts Remember to keep complete records of mainte nance and repair with dates and any new parts installed H o w to Use this Manual In preparing this manual we divided the product into its major systems These systems became the man
117. ervoir damper adjuster to the softest position Install the air bleeder bolt OCheck the O ring on the air bleeder bolt and replace it if necessary Pour SAE 5W or Bel Ray SE2 40 oil into the gas reservoir to 60 70 mm A from the gas reservoir upper end Check that the bladder A on the gas reservoir cap is not partially collapsed l f it is push down the valve core with a screwdriver Check the bladder for signs of damage or crack f necessary replace it with a new one CAUTION Do not use a damaged or partially collapsed bladder because it may burst gently reducing rear shock performance Apply grease to the lip B of the bladder Push the bladder and gas reservoir cap into the gas reservoir slowly until it just clears the circlip groove Wipe out any spilled oil CAUTION Ensure that no air remains in the system Check the circlip for weakening deformity and flaws l f necessary replace it with a new one http mototh com SUSPENSION 12 23 AWARNING If weakened deformed or flawed circlip is used the gas reservoir cap may not hold when injecting the nitrogen gas This would allow oil and internal parts to explode out of the reservoir Mount the circlip A in the groove in the gas reservoir gt Pull up the gas reservoir cap A against the circlip The end of the gas reservoir cap must align C with the end of the gas reservoir B AWARNING If the end of the ga
118. ery time they are removed These replacement parts will be damaged or lose their original function once removed 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts http mototh com 1 4 GENERAL INFORMATION Model Identification KLX250 D1 KLX250 D2 KLX250 D3 KLX250 D4 http mototh com GENERAL INFORMATION 1 5 KLX250 E1 KLX250 E2 KLX250 E3 http mototh com 1 6 GENERAL INFORMATION General Specifications Items KLX250 D1 D2 D3 D4 Dimensions Overall length 2115 mm Overall width 910 mm Overall height 1220 mm Wheelbase 1435 mm Road clearance 320 mm Seat height 925 mm Dry weight 104 kg Curb weight Front 53 kg Rear 59 kg Fuel tank capacity 8 L Engine Type 4 stroke DOHC 1 cylinder Cooling system Liquid cooled Bore and stroke 72 0 x 61 2 mm Displacement 249 mL Compression ratio 1 1 0 1 Maximum horsepower 23 5 KW 32
119. eturn to the seat width measure ment step above Lap the valve to the seat using a lapper once the seat width and O D are within the ranges specified above O Put a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding compound produces a smooth matched surface on both the seat and the valve O Repeat the process with a fine grinding compound A Lapper B Valve Seat C Valve The seating area should be marked about in the middle of the valve face l f the seat area is not in the right place on the valve check to be sure the valve is the correct part If the valve is correct the valve may have been refaced too much replace the valve Be sure to remove all grinding compound before assembly When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment http mototh com Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface Move the stem back and forth C to measure valve to valve guide clearance O Repeat the measurement in a direction at a right angle to th
120. g Bolts Right Engine Cover Bolts Magneto Cover Bolts 15 78 3 2 12 29 98 120 9 8 9 8 5 4 9 8 15 25 9 8 9 8 9 8 9 8 1 5 8 0 0 33 1 2 3 0 10 0 12 0 1 0 1 0 0 55 1 0 1 5 2 5 1 0 1 0 1 0 1 0 11 0 58 29 in lb 8 5 22 0 72 87 87 in lb 87 in lb 48 in lb 87 in lb 11 0 18 0 87 in lb 87 in lb 87 in lb 87 in lb L L L L L L http mototh com GENERAL INFORM ATION 1 15 FFFaaasssttteeennneeerrr Torque RRReeem m maaarrrkkksss N m kg m ft lb Engine Lubrication System Engine Oil Drain Plug Oil Pressure Relief Valve Oil Pipe Banjo Bolts 08 010 Oil Pump Mounting Screws 15 15 9 8 20 5 4 1 5 1 5 1 0 2 0 0 55 11 0 11 0 87 in lb 14 5 48 in lb L Engine Removal Installation Swing Arm Pivot Shaft Nut Engine Mounting Nuts Cylinder Head Bracket Bolts 8 O10 88 44 29 44 9 0 4 5 3 0 4 5 65 33 22 33 Crankshaft Transmission Shift Drum Bearing Retaining Bolts Crankcase Bolts 1 2 9 8 9 8 15 1 0 1 0 1 5 87 in lb 87 in lb 11 0 Wheel Tires Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut Spoke Nipples 88 9 8 98 Not less than 1 5 9 0 1 0 10 0 Not less than 0 15 65 87 in lb 72 Not less than 13 in lb Final Drive Rear Sprocket Nuts Swing Arm Pivot Shaft Nut Tie Rod Upper Mounting Nut Rear Axle Nut 29 88 81 98 3 0 9 0 8 3 10 0 22 65 60 72 Brakes Brake Hose Banjo Bolts Fron
121. g from insulation brakedown under high voltage http mototh com 15 14 ELECTRICAL SYSTEM Remove the ignition coil Measure the primary winding resistance A O Connect an ohmmeter between the coil terminals OSet the meter to the x 1 Q range and read the meter Measure the secondary winding resistance B Pull the spark plug cap off the lead Connect an ohmmeter between the spark plug lead and the ground lead terminal OSet the meter to the x 1 kQ range and read the meter l f the meter does not read as specified replace the coil l f the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good Ignition Coil Winding Resistance Primary windings 0 2 Q 15 at 20 C Secondary windings 6 3 kQ 20 at 20 C Check the spark plug lead for damage l f the spark plug lead is damaged replace the coil Spark Plug Cleaning and Inspection Remove the spark plug and visually inspect it Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool l f the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark
122. ge make the 32 grind described below frlf the outside diameter of the seating surface is within the specified range measure the seat width as described below Grind the seat at a 32 angle until the seat O D is within the specified range http mototh com 4 22 ENGINE TOP END OTo make the 32 grind fit a 32 cutter to the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to prevent overgrinding O After making the 32 grind return to the seat O D measurement step above To measure the seat width use a vernier caliper to measure the width of the 45 angle portion of the seat at several places around the seat l f the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat O D measurement step above l f the seat width is too wide make the 60 or 55 grind described below If the seat width is within the specified range lap the valve to the seat as described below Grind the seat at a 60 or 55 angle until the seat width is within the specified range OTo make the 60 or 55 grind fit 60 or 55 cutter to the holder and slide it into the valve guide OTurn the holder while pressing down lightly O After making the 60 or 55 grind r
123. haft s and or cylinder head are replaced with new ones apply a thin coat of molybdenum disulfide grease to the new cam part surfaces Install the inlet and exhaust camshafts OThe exhaust camshaft A has the compression release mechanism B Be careful not to mix up these shafts when installing NOTE O Be sure to set properly the camshaft chain timing when installing the camshaft Remove the two caps on the alternator cover Position the crankshaft at TDC O Using a wrench on the crankshaft rotation bolt A turn the crankshaft counterclockwise B until the T mark C on the magneto flywheel is aligned with the notch D in the edge of the upper hole in the magneto cover Engage the camshaft chain with the camshaft sprockets O Pull the tension side exhaust side of the chain taut to install the chain OThe timing marks on the exhaust sprocket must be aligned with the cylinder head upper surface and pointed toward the front Pull the chain taut and fit it onto the camshaft sprocket Starting with the timing mark on the front of the exhaust sprocket count to the 32nd pin Feed the exhaust camshaft through the chain and align the 32nd pin with the timing mark on the inlet camshaft sprocket http mototh com 4 10 ENGINE TOP END Install the camshaft cap Tighten the cap bolts following the tightening sequence shown in the figure OThe sequence numbers are marked on the cap Install Cam Chain T
124. he front disc turn the handlebar fully to one side Measure the disc runout while rotating B the wheel slowly l f the runout exceeds the service limit replace the disc Runout Standard Service Limit Not more than 0 12 mm 0 3 mm http mototh com BRAKES 11 17 Brake Hose Removal Installation Notes CAUTION Brake fluid quickly ruins painted or plated surfaces any spilled fluid should be completely wiped up immediately with damp cloth When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum There are washers on each side of the brake hose fitting Replace them with new ones when installing When installing the hoses avoid sharp bending kinking flatting or twisting and route the hoses according to the Cable Wire and Hose Routing section in the General Information chapter Torque the banjo bolts at the hose fittings Torque Brake Hose Banjo Bolts 25 N m 2 5 kg m 18 0 ft lb Bleed the brake line after installing the brake hose see Bleeding the Brake Line Inspection The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly maintained Bend and twist the rubber hose while examining it Replace it if any cracks or bulges are noticed http mototh com
125. he oil seal removed with a new one Insert the cylinder unit B into the inner tube A Install the cylinder base C onto the cylinder unit Insert the inner tube and cylinder unit as a set into the outer tube Visually inspect the cylinder valve assembly A for damages and replace it if necessary A p p l y a liquid gasket to both sides of the gasket and apply a non permanent locking agent to the threads of the cylinder valve assembly at the bottom of the outer tube Stop the cylinder from turning by using the fork cylinder holder handle and adapter tighten the cylinder valve assembly Special Tools Fork Cylinder Holder Handle 57001 183 Fork Cylinder Holder Adapter 57001 1057 Torque Cylinder Valve Assembly 71 N m 7 2 kg m 52 tt lb Install the cap on the bottom of the outer tube When replacing the outer tube guide bushing with a new one hold the used guide bushing against the new one and tap the used guide bushing with the front fork oil seal driver until it stops The slit in the bushing must face toward the wheel Special Tool Front Fork Oil Seal Driver 57001 1219 A Front Fork Oil Seal Driver B Used Guide Bushing C Slit faces toward the wheel D New Guide Bushing E Outer Tube F Tap After installing the washer install the oil seal by using the fork oil seal driver Using the fork oil seal driver install the dust seal Pour in the type and amount of fork o
126. he radiator filler by removing the cap If the cap is removed air may get into the coolant passages and lower the cooling efficiency l f the amount of coolant is insufficient unscrew the cap from the reservoir tank add coolant through the filler opening to the FULL mark then install the cap CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorro sion properties The diluted coolant can attack the aluminum engine parts In an emergency soft water can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks http mototh com Coolant Change The coolant should be changed periodically to ensure long engine life Coolant Draining AWARNING Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking Remove the radiator cover A Remove the radiator cap B in two steps First turn the cap counter clockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap NOTE O Positi
127. he switch A in a container of water so that the temperature sensing projection and threaded portion are submerged Suspend an accurate thermometer B in the water NOTE O The switch and thermometer must not touch the container sides or bottom Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently Using the hand tester measure the internal resistance of the temper atures shown below l f the hand tester does not shown the specified values replace the switch Water Temperature Sensor Resistance O Rising temperature From OFF to On at 107 113 C 255 236 F O Falling temperature From ON to OFF at 103 106 C 217 223 F ON Less than 0 5 Q OFF More than 1 MQ http mototh com Lighting System ELECTRICAL SYSTEM 15 23 The KLX250E Australia model has a headlight relay In this model the headlight does not go on when the ignition switch and the engine stop switch are first turned on The headlight comes on after the starter button is released and stays on until the ignition switch is turned off The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released Headlight Beam Adjustment Adjust the headlight so that it points slightly below horizontal Turning the adjusting screw A clockwise makes the headlight beam point upward Headlight Bulb Replacement Notes CAUT
128. he washers that are on each side of hose fitting with new ones Tighten the rear axle nut Torque Caliper Mounting Bolts 25 N m 2 5 kg m 18 0 ft lb Brake Hose Banjo Bolt 25 N m 2 5 N m 18 0 ft lb Rear Axle Nut 98 N m 10 0 kg m 72 ft lb http mototh com 11 10 BRAKES Bleed the brake line see Bleeding the Brake Line Check the brake for good braking power no brake drag and no fluid leakage AWARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first application of the lever or pedal if this is not done Disassembly Remove the front rear caliper Remove the pads and spring see Pad Removal Remove the caliper holder shaft rubber friction boot and cover Using compressed air remove the piston s OCover the caliper opening with a clean heavy cloth A O Remove the piston s by lightly applying compressed air B to where the brake line fits into the caliper AWARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply compressed air into the caliper the piston s may crunch your hand or fingers NOTE O f the caliper is to be disassembled after removal and if compressed air is not available remove the piston s using the following three steps before disconnecting the brake hose from the c
129. hen cold KLX250D Front Rear Standard 100 kPa 1 0 kg cm2 14 psi KLX250E Front 150 kPa 1 5 kg cm2 21 psi Rear 150 kPa 1 5 kg cm2 21 psi up to 97 5 kg 175 kPa 1 75 kgl cm2 25 psi 97 5 181 kg http mototh com Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Remove the wheel from the motorcycle see this chapter To maintain wheel balance mark A the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position Take out the valve B to let out the air OWhen handling the rim be careful not to damage the rim flanges Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with mineral oil engine oil or gasoline because they will cause deterioration of the tire Break the beads away from both sides of the rim with the bead breaker Special Tool Bead Breaker Assembly 57001 1072 A Pry the tire off the rim with the tire iron portion of the bead breaker B protecting the rim with rim protectors A Special Tools Rim Protector 57001 1063 A Tire Iron Portion of the Bead Bead Breaker Assembly 57001 1072 Installation Notes Position the tire on the rim so that the valve B is
130. him and then measure the clearance again http mototh com ENGINE TOP END 4 19 VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1 Measure the clearance with engine cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 65 mm Measured clearance is 0 35 mm Replace 2 65 mm shim with 2 85 mm shim 5 Remeasure the valve clearance and readjust if necessary CAUTION Be sure to remeasure the clearance after selecting a shim according to the table The clearance can be out of the specified range because of the shim tolerance http mototh com 4 20 ENGINE TOP END Guide Installation Drive the valve guide in from the top of the cylinder head until the circlip stops the guide from going in too far NOTE OApply engine oil to the valve guide outer surface Heat the area around the valve guide hole to about 120 150 C 248 302 F Ream the valve guide with the valve guide reamer A even if the old guide is reused Special Tools Valve Guide Arbor 04 5 57001 1331 Valve Guide Reamer 4 5 57001 1333 Seat Inspection Remove the valve Check the valve seat surface A between the valve B and valve seat C O Measure the outside diameter D of the seating pattern on the valve seat l f the outside di
131. iator Radiator Removal Remove the radiator cover Drain the coolant see Coolant Draining Remove the fuel tank Loosen the hose clamps and pull off the water and breather hoses Remove the mounting bolts and take out the radiator with the radiator louver Radiator Installation Installation is the reverse of removal see Coolant Filling Radiator Inspection Check the radiator core l f there are obstructions to air flow remove them l f the corrugated fins are deformed carefully straighten them with the blade of a thin screwdriver A CAUTION Do not tear the radiator tubes while straightening the fins l f the air passages of the radiator core are blocked more than 20 by irremovable obstructions or irreparably deformed fins replace the radiator with a new one CAUTION When cleaning the radiator with compressed air be careful of the following to avoid damage to the fins Keep the air nozzle over 0 5 m 20 in away from the radiator Blow air perpendicularly to the radiator core Never blow air at an angle against the fins but straight through them in the direction of natural air flow Never shake the air nozzle at a right angle against the fins be sure to move it at a level with the fins Radiator Cap Inspection Check the condition of the valve spring A and the top B and bottom C valve seals of the radiator cap l f any one of them shows visible damage replace the cap
132. ide Covers Seat Disconnect the magneto lead Zero the ohmmeter and connect it to the stator coil lead terminals One Yellow and Another Yellows in the connector Stator Coil Resistance KLX250D Y Y 0 2 0 8 D W R 100 190 Q KLX250E Y Y 0 4 1 1 Q Note the resistance reading l f there is more resistance than shown the stator has a broken wire the leads between the stator and the connector are open or the connections are bad Check the stator and the leads and fix or replace the damaged parts l f there is much less resistance than shown the stator is shorted or the leads between the stator and the connector is grounded Check the stator and the leads and fix or replace the damaged parts Interlock Diode Unit Inspection KLX250E Remove the seat Remove the interlock diode unit A from the motorcycle Zero the hand tester and connect it to the diode unit terminals Special Tool Hand Tester 57001 983 Check the resistance between the terminals following the table The diode resistance should be low in one direction and more than ten times as much in the other direction If any two leads are low or high in both directions the diode is defective and must be replaced NOTE OThe actual meter reading varies with the meter used and the individual diode but generally speaking the lower reading should be from zero to one half the scale http mototh com ELECTRICAL SYSTEM 15 17 Diode U
133. ier 8 Magneto http mototh com Switches KLX250E ELECTRICAL SYSTEM 15 29 Brake Light Timing Inspection T u rn the ignition switch to the ON position Start the engine Check the operaiton of the rear brake light switch by depressing the brake pedal f the light does not go on as specified adjust the brake light timing Brake Light Timing Standard On after about 10 mm of pedal travel A Brake Light Timing Adjustment Brake light timing is adjusted changing the position of the rear brake light switch Adjust the position of the switch so that the brake light goes on after the specified pedal travel by turning the adjusteing nut A CAUTION To avoid damaging the electrical connections inside the switch be sure that the switch body does bot turn during adjustment Switch Inspection Using a hand tester check to see that only the connections shown in the table have continuity about zero ohms OFor the handlebar switches and the ignition switch refer to the tables in the Wiring Diagram l f the switch has an open or short replace it with a new one Special Tool Hand Tester 57001 983 Rear Brake Light Switch Connections Side Satnd Switch Connections http mototh com APPENDIX 16 1 Appendix Table of Contents Additional Considerations for Racing KLX250E 16 2 Carburetor 16 2 Spark Plug 16 2 Spark Plug Inspection 16 3 Troubleshooting Guide 16 4 Engine Doesn t
134. ight Front 54 kg Rear 60 kg Fuel tank capacity 9 8 L Engine Type 4 stroke DOHC 1 cylinder Cooling system Liquid cooled Bore and stroke 78 0 x 61 2 mm Displacement 292 mL Compression ratio 11 0 1 Maximum horsepo wer 24 3 KW 33 PS 8 500 r min rpm US 19 1 KW 26 PS 7 000 r min rpm Maximum torque 28 4 N m 2 9 kg m 21 ft lb 7 500 r min rpm US 27 5 N m 2 8 kg m 20 ft lb 6 500 r mm rpm Carburetion system Carburetor KEIHIN CVK34 Starting system Primary kick Ignition system CDI Timing advance Electronically advanced Ignition timing From 10 BTDC 1 700 r min rpm to 40 BTDC 3 000 r min rpm Spark plug NGKDR8E NDX24ESR N Cylinder numbering method Firing order Valve timing Inlet Open 22 BTDC Close 62 ABDC Duration 264 Exhaust Open 61 BBDC Close 19 ATDC Duration 260 Lubrication system Forced lubrication wet sump Engine oil Grade SE SF or SG class Viscosity SAE10W 40 10W 50 20W 40 or 20W 50 Capacity 1 5 L http mototh com 4 Items KLX300 A2 Drive Train Primary reduction system Type Gear Reduction ratio 2 863 62 22 Clutch type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear ratios 1st 3 000 30 10 2nd 2 000 30 15 3rd 1 500 27 18 4th 1 250 25 20 5th 0 050 21 20 6th 0 904 19 21 Final drive system Type Chain drive Reduct
135. ighten the axle nut Torque Axle Nut 98 N m 10 kg m 72 ft lb Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary Insert a new cotter pin through the axle nut and axle and spread its end AWARNING If the axle nut is not securely tightened and the cotter pin is not installed an unsafe riding condition may result Check the rear brake effectiveness Wheel Alignment Inspection Check that the notch on the left chain adjuster aligns with the same swingarm mark as the right chain adjuster notch aligns with NOTE O Wheel alignment can also be checked using the straightedge or string method AWARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition http mototh com 10 6 FINAL DRIVE Wheel Alignment Adjustment This procedure is the same as Slack Adjustment Drive Chain Wear Inspection Rotate the rear wheel to inspect the drive chain for damaged rollers and loose pins and links l f there is any irregularity replace the drive chain Lubricate the drive chain if it appears dry Stretch the chain taut by hanging a 10 kg 20 lb weight A on the chain Measure B the length of 20 links on the straight part C of the chain from the pin center of the 1 st pin to the pin center of the 21 st pin Since the chain may wear unevenly take measurement at several places l f any measureme
136. il A loss in flywheel magnetism which may be caused by dropping or hitting the flywheel or just be aging will result in low output Therefore inspect the flywheel magneto first measure the output next inspect the coils and the flywheel see Charging System Ignition System http mototh com 15 12 ELECTRICAL SYSTEM Charging System Regulator Inspection Turn off the ignition switch Remove the left side cover Remove the regulator A Set the hand tester x 1 kQ range and connect it to the terminals in the regulator connector and check the resistance in both directions of each diode following the table Special Tool Hand Tester 57001 983 l f the readings do not correspond to the table replace the regulator Regulator Internal Resistance KLX250D Unit kQ Meter Negative Lead Connection Meter Negative Lead Connection http mototh com ELECTRICAL SYSTEM 15 13 Ignition System Safety Instructions AWARNING The Ignition system produces extremely high voltage Do not touch the spark plug high tension coil or spark plug lead while the engine is running or you should receive a severe electrical shock CAUTION Do not disconnect electrical connections while the engine is running This is to prevent ignition coil damage Ignition Coil Removal Remove Seat Radiator Covers Fuel Tank Disconnect the ignition coil primary leads A Pull the plug cap off the
137. il specified and adjust the oil level see Fork Oil Change Special Tool Front Fork Oil Seal Driver 57001 1219 Fork Oil Viscosity KAYABA 01 or SAE5W Inner Tube Inspection Visually inspect the inner tube repair any damage Nicks or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage l f the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced Temporarily assemble the inner and outer tubes and pump back and forth manually to check tube smooth operation http mototh com 12 10 SUSPENSION CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Guide Bushing Inspection Visually inspect the guide bushings A and replace them if necessary Oil Seal and Dust Seal Inspection Inspect the dust seal B for any signs of deterioration or damage Replace it if necessary Replace the oil seal A with a new one whenever it has been removed Spring Tension Since a spring A becomes shorter as it weakens check its free length to determine its condition l f the spring of either fork leg is shorter than the service limit it must be replaced If the length of replacement spring and that of the remaining spring vary greatl
138. ill not function on the first application of the lever if this is not done http mototh com WHEELS TIRES 9 5 Rear Wheel Removal Raise the rear wheel off the ground Special Tool Jack 57001 1238 Remove the clip from the master link using pliers and free the drive chain from the rear sprocket Remove the cotter pin A Remove the axle nut B Pull out the axle C and remove the chain adjuster and rear wheel CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Insert a wood wedge between the brake pads this prevents them from I being moved out of their proper position should the brake pedal be squeezed accidentally Rear Wheel Installation Notes Fit the brake holder stop A against the swingarm stop B Install the collars A on the left and right side of the hub Install the drive chain Install the master link clip A so that the closed end of the U points in the direction of chain rotation B http mototh com 9 6 WHEELS TIRES Check the drive chain slack see Drive Chain Slack Inspection in the Final Drive chapter Torque the following Torque Rear Axle Nut 98 N m 10 kg m 72 ft lb Rear Caliper Mounting Bolts 25 N m 2 5 kg m 18 ft lb Install a new cotter pin Check the rear brake AWARNING Do not
139. ing Remove the radiator cover Remove the radiator cap and install a cooling system pressure tester A on the radiator filler neck NOTE O Wet the adapter B cap sealing surfaces with water or coolant to prevent pressure leaks Build up pressure in the system carefully until the pressure reaches 123 kPa 1 25 kg cm2 18 psi Watch the gauge for at least 6 seconds If the pressure holds steady the cooling system is all right CAUTION During pressure testing do not exceed the pressure for which the system is designed The maximum pressure is 123 kPa 1 25 kg cm2 18 psi l f the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks Remove the pressure tester replenish the coolant and install the radiator cap http mototh com 3 10 COOLING SYSTEM Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cooling system If this accumulation is not removed it will clog up the water passages and considerably reduce the efficiency of the cooling system Drain the cooling system Fill the cooling system with fresh water mixed with a flushing compound CAUTION Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by
140. ing no hydrogen gas Moreover the oxygen gas generated from the positive plate immediately reacts with the charged active material on the negative plate and returns to water with the ultimate result of no water loss Pb 1 2 02 PbO Negative active Oxygen generated Negative active material from positive plate material charged state PbO H2SO4 PbS04 H2O Electrolyte Negative active Water material charged state Thus the negative plate is made as not to get fully charged Even if the overcharge continues the oxygen gas generated inside the battery is absorbed by the negative plate a process called oxygen cycle which keeps water loss theoretically at nil and allows the battery to be sealed TV Filling the Battery with Electrolyte CAUTION Do not remove the aluminum seal sheet sealing the filler ports until just before use Be sure to use the dedicated electrolyte container for correct electrolyte volume Check to see that there is no peeling tears or holes in the sealing sheet Place the battery on a level surface Remove the sealing sheet OWhen removing check to hear an air sucking sound Shoosh from filler ports NOTE OA battery whose sealing sheet has any peeling tears holes or from which the air sucking sound was not heard requires a refreshing charge initial charge 1 Sealing Sheet 2 Filler Ports Take the electrolyte container out of the vinyl bag
141. ion ratio 3 571 50 14 Overall drive ratio 9 253 Top gear Frame Type Tubular semi double cradle Caster rake angle 26 5 Trail 107 mm Front tire Type Tube K490 Size 80 100 18 59M Rear tire Type Tube K695 Size 100 100 18 59P Front suspension Type Telescopic fork Wheel travel 290 mm US CN 285 mm Rear suspension Type Swingarm Uni trak Wheel travel 280 mm Brake type Front Single disc Rear Single disc Electrical Equipment Headlight Type Semi sealed beam Bulb 12 V 30W Tail Brake Light 12V 10W Alternator Type Three phase AC Rated output Specifications subject to change without notice and may not apply to every country CN Canada Model US U S Model http mototh com 5 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition Continued on next page ENGINE Clutch adjust Clutch and friction plates check Throttle cables adjust Spark plug clean check Valve clearance check Air cleaner element clean Air cleaner element replace Carburetor inspect adjust Spark arrestor US clean Oil filter replace Engine oil change Engine sprocket check Coolant change Radiator hoses connections check CHASSIS Brake adjustment check Brake pad wear check Brake fluid level check
142. ire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion M O T E O Prior to grinding apply engine oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following 60 Cutter angle B 37 50 Outer diameter of cutter C Operating Procedures Clean the seat area carefully Coat the seat with machinist s dye Fit a 45 cutter to the holder and slide it into the valve guide Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylinder head must be replaced Measure the outside diameter of the seating surface with a vernier caliper l f the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the specified range l f the outside diameter of the seating surface is too lar
143. is the amount of runout Set a dial gauge against the outer circumference of the rim and rotate the rim to measure the radial runout D The difference between the highest and lowest dial readings is the amount of runout l f rim runout exceeds the service limit check the wheel bearings first Replace them if they are damaged If the problem is not due to the bearings correct the rim warp runout A certain amount of rim warp can be corrected by recentering the rim Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim If the rim is badly bent however it must be replaced Rim Runout with tire installed Standard Axial 0 5 mm Radial 0 8 mm service Limit 2 0 mm Axle Inspection Place the axle in V blocks that are 100 mm A apart and set a dial gauge on the axle at a point halfway between the blocks Turn the axle to measure the runout The difference between the highest and lowest dial readings is the amount of runout frlf runout exceeds the service limit replace the axle Axle Runout 100 mm Standard Under 0 10 mm Service Limit 0 2 mm WHEELS TIRES 9 7 http mototh com 9 8 WHEELS TIRES Tires Inspection As the tire tread wears down the tire becomes more susceptible the puncture and failure An accepted estimate is that 90 of all tire failures occur during the last 10 of tread life 90 worn So it is false economy and unsafe to
144. k P U P u r p l e R Red W White Y Ye I low http mototh com EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Additionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the carburetion system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere Instead fuel vapors are routed into the running engine to be burned or stored in a canister whe
145. l 3 CDI Unit 4 Magneto 5 Pickup Coil KLX250E 1 Ignition Switch 2 Engine Stop Switch 3 Regulator Rectifier 4 Side Stand Switch 5 Ignition Coil 6 Neutral Indicator Light 7 Neutral Switch 8 Interlock Diode Unit 9 Starter Lockout Switch 10 I C Igniter 11 Magneto 12 Pickup Coil http mototh com 15 22 ELECTRICAL SYSTEM Thermostatic Fan Switch Inspection Remove the fan switch from the radiator see Thermostatic Fan Switch Removal in the Cooling System chapter Suspend the switch A in a container of water so that the temperature sensing projection and threaded portion are submerged Suspend an accurate thermometer B in the water NOTE O The switch and thermometer must not touch the container sides or bottom Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently Using the hand tester special tool measure the internal resistance of the switch across the connector and the body at the temperatures shown below l f the hand tester does not show the specified values replace the switch Fan Switch Resistance O Rising temperature From OFF to ON at 94 O Falling temperature From ON to OFF at 90 ON Less than 0 5 Q OFF More than 1 NlO 100 C 201 2 1 2 T 93 C 194 199 F Water Temperature Sensor Inspection Remove the water temperature sensor see Cooling System chapter Suspend t
146. l A lips and oil the oil seal outside circular surface Press the oil seal into the hole from the inside of the right engine cover with a bearing driver set B so that the spring side of the seal lips is toward the inside of the cover Special Tool Bearing Driver Set 57001 1129 CAUTION Use the larger bearing driver in diameter than the oil seal and press the oil seal into the hole until the edge of the oil seal is flush with the step D for the bail bearing After installing the mechanical seal there should be about 0 8 mm clearance between the seals for the drainage passage Press the ball bearing into the hole with a bearing driver set until the bearing is bottomed against the step O Press the ball bearing with its sealed side facing to the oil seal Special Tool Bearing Driver Set 57001 1129 Press the mechanical seal into the hole with a bearing driver set until its flange touches the step CAUTION Never tap on the mechanical seal use a press only Be careful not to damage the sealing surface of the mechanical seal A Bearing Driver Set B Mechanical Seal C Oil Seal D Touch the Step E Clearance about 0 8 mm Mechanical Seal Inspection Visually inspect the mechanical seal l f any one of the parts is damaged replace the mechanical seal as a unit A Impeller Sealing Seat Surface IB Rubber Seal C Mechanical Seal Diaphragm http mototh com 3 14 COOLING SYSTEM Rad
147. l stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is Stoddard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket 0 Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Loctite Lock n Seal Blue 10 Press A part installed using a press or driver such as a wheel bearing should first be coated with oil on its outer or inner circumference so that it will go into place
148. lation Notes Shaft Disassembly Note Using outside circlip pliers to remove the circlips disassemble the transmission shaft Special Tool Outside Circlip Pliers 57001 144 Shaft Assembly Notes Apply engine oil liberally to the transmission shaft gears and bearings Replace any circlips that were removed with new ones OAlways install circlips A so that the opening B is aligned with a spline groove C and install toothed washers D so that the teeth E are not aligned with the circlip opening B To install a circlip without damage first fit the circlip onto the shaft expanding it just enough to install it and then use a suitable gear to push the circlip into place Special Tool Outside Circlip Pliers 57001 144 The drive shaft gears can be identified by size the smallest diameter gear is 1 st gear and the largest is 6th Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and the washers are properly in place 1 1 st gear 10T part of drive shaft A 2 5th gear 20T gear dogs left B 3 3rd 4th gear 18T 20T larger gear faces right C 4 6th gear 21T gear dogs right D 5 2nd gear 15T Plain side faces left E http mototh com 8 12 CRANKSHAFT TRANSMISSION The output shaft gears can be identified by size the largest diameter gear is 1 st gear and the smallest is 6th Be sure that all parts are put back in the corr
149. light bulb the neutral switch the interlock diode unit see this chapter and the wiring see Wiring Inspection 2 The warning light does not flash when the water temperature is high with the transmission in gears Check the water temperature warning light operation see below 3 Coolant temperature is not high but the warning light stays on continuously Check the warning circuit wiring l f it is good check the water temperature sensor A see this chapter 4 Warning light goes on and off irregularly Check that the wiring is not shorting out against other parts l f all the above checks are good check the water temperature sensor see this chapter Warning Light Operation Inspection Pull off the neutral switch connector and the water temperature switch connector Turn the ignition switch to the ON position Start the engine Ground the water temperature sensor connecter to the engine l f the water temperature warning light does not come on check the water temperature warning light and the warning circuit wiring see Wiring Inspection l f the water temperature warning light comes on check the water temperature sensor see this chapter http mototh com 15 28 ELECTRICAL SYSTEM Coolant Temperature Warning Circuit 1 Ignition Switch 2 Coolant Temperature Warning Light 3 Coolant Temperature Sensor 4 Interlock Diode Unit 5 Diode 6 Neutral Switch 7 Regulator Rectif
150. ll ventilated and free from any source of flame or sparks this includes any appliance with a pilot light CAUTION During carburetor disassembly be careful not to damage diaphragm Never use a sharp edge to remove the diaphragm site Turn in the pilot screw and count the number of turns until it seats fully but not tightly and then remove the screw This is to set the screw to its original position when assembling Turn in the pilot screw fully but not tightly and then back it out the same number of turns counted during disassembly Turn the carburetor body upside down and drop the needle jet A into place so that the smaller diameter end B of the jet goes in first Carefully screw in the needle jet holderfA It will seat against the needle jet pushing the end of the jet into the carburetor bore CAUTION Do not force the needle jet holder air bleed pipe and main jet A or overtighten them They could be damaged requiring replacement Cleaning AWARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetor CAUTION Do not use compressed air on an assembled carburetor or the float may be crushed by the pressure and the vacuum piston diaphragm may be damaged Rem
151. llation Note 3 18 Thermostatic Fan Switch Inspection 3 18 Water Temperature Sensor Removal 3 18 Water Temperature Sensor Installation Notes 3 18 Water Temperature Sensor Inspection 3 18 http mototh com 3 2 COOLING SYSTEM Exploded View KLX250D T 1 7 8 N m 0 8 kg m 69 in lb T2 25 N m 2 5 kg m 18ft lb T3 9 8 N m 1 0 kg m 87 in lb http mototh com COOLING SYSTEM 3 3 KLX250E http mototh com 3 4 COOLING SYSTEM Specifications Items Standard Recommended Coolant Type Color Mixed ratio Freezing point Total amount Permanent type of antifreeze for aluminum engines and radiators Green Soft water 50 coolant 50 35 0C 31 F 1 6 L Radiator Cap relief pressure 9 3 1 2 3 kPa 0 95 1 25 kg cm2 1 4 1 8 psi Thermostat Valve opening temperature Valve full opening lift 69 5 72 5 C 157 162 F 3mm or more 85 C 185 F Special Tool Bearing Driver Set 57001 1129 http mototh com COOLING SYSTEM 3 5 Cooling System The water cooling system is a pressurized forced circulation type When the engine load varies this system controls the engine temperature within narrow limits where the engine operates most efficiently In this way the engine performs stably in various riding conditions and possesses high durability KLX250D KLX250E 1 Radiator Cap 2 To Reservoir Tank 3 Radiator 4 Water Pump 5 To Cylinder Jacket 6 From Cylinder Head 7 Thermosta
152. locknut A with the steering stem nut wrench B to obtain the proper adjustment l f the steering is too tight loosen the stem locknut a fraction of a turn if the steering is too loose tighten the locknut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE O Turn the locknut 7 8 turn at a time max mum Torque the following Torque Steering Stem Head Nut 44 N m 4 5 kg m 33 ft lb Front Fork Lower Clamp Bolts 20 N m 2 0 kg m 14 5 ft lb http mototh com STEERING 13 5 Mount the handlebar clamps B so that the arrow C on the clamp point at the front A OTorque the handlebar clamp bolts Torque Handlebar Clamp Bolts 25 N m 2 5 kg m 18 ft lb OTighten the clamp bolts front first and then the rear If the handlebar clamp is correctly installed there will be no gap A at the front and a gap B at the rear after tightening Stem Stem Bearing Removal Remove Meter Cable Lower End Front Wheel Brake Hose Clamp Caliper Mounting Bolts Master Cylinder Clamp Front Fender Headlight and Meter Unit Handlebar Front Fork Remove the steering stem head nut and washer Remove the steering stem head Pushing up on the stem base A and remove the steering stem locknut B with the steering stem nut wrench D then remove the steering stem C and stem base Special Tool Steering Stem Nut Wrench 57001 1100 Take off the upper stem bearing inner race
153. lowing technical information may prove useful However please note the following important notes You are entirely responsible for the use of your motorcycle under abnormal conditions such as racing and Kawasaki shall not be liable for any damages which might arise from such use Kawasaki s Limited Motorcycle Warranty and Limited Emission Control Systems Warranty specifically exclude motorcycles which are used in competition or related uses Please read the warranty carefully Motorcycle racing is a very sophisticated sport subject to many variables The following information is theoretical only and Kawasaki shall not be liable for any damages which might arise from alterations utilizing this information When the motorcycle is operated on public roads it must be in its original state in order to ensure safety and compliance with applicable regulations Carburetor Sometimes an alteration may be desirable for improved performance under special conditions when proper mixture is not obtained after the carburetor has been properly adjusted and all parts cleaned and found to be functioning properly If the engine still exhibits symptoms of overly rich or lean carburetion after all maintenance and adjustments are correctly performed the main jet can be replaced with a smaller or larger one A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture Spark Plug The spark plug ignites the fuel and air
154. lts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads General Fasteners TTThhhrrreeeaaadddsss dddiiiaaa m mmm mm Torque N m kg m ft lb 5 6 8 10 12 14 16 18 20 3 4 4 9 5 9 7 8 14 19 25 34 44 6 1 73 98 115 155 165 2 2 5 225 325 0 35 0 50 0 60 0 80 1 4 1 9 2 6 3 5 4 5 6 2 7 4 10 0 11 5 16 0 17 0 23 0 23 33 30 43 in lb 52 69 in lb 10 0 13 5 19 0 25 0 33 45 54 72 83 115 1 2 5 1 6 5 165 240 http mototh com 10 Cables Wires and Hoses Piping Diagram 1 Throttle Cable decelerate side 2 L shaped Joint 3 Direction of Travel Be sure to install and fix the L shaped joint of the decelerate side facing 45 degrees to the direction of travel http mototh com 11 Fuel System Specifications Item Standard Throttle Grips and Cables Throttle Grip Free Play 2 3 mm Carburetor Make type Pilot screw turns out Service fuel level Float height Main jet Main air jet Jet needle mark Jet needle clip position Slow jet Slow air jet Starter jet Air Cleaner Element Oil KEIHIN CVK34 2 1 2 1 5 mm above 0 5 mm below the float bowl mating surface 17 2 mm 128 50 N3RA 3rd groove from the top 35 115 40 2 stroke racing oil or high quality foam air filter oil http mototh com 12 Engine Top End Specifications Item Sta
155. ly http mototh com 3 16 COOLING SYSTEM Radiator Fan KLX250E Removal Remove Radiator Covers Seat Fuel Tank Disconnect Fan Motor Lead Connector Installation Notes Route the fan motor lead and the fan switch lead in accordance with the Cable Wire and Hose Routing in the General Information chapter Remove the fan motor B mounting bolts A and take off the fan motor http mototh com COOLING SYSTEM 3 17 Thermostat KLX250E Removal Drain the coolant see Coolant Change Remove the thermostat housing cap A bolts and take the thermostat out of housing Installation Note Put the thermostat A into the housing so that the air bleeder hole B is positioned toward the rear of the engine Torque Thermostat Housing Cap Bolts 9 8 N m 1 0kg m 87 in lb Inspection Remove the thermostat B and inspect the thermostat valve at room temperature l f the valve is open replace the valve with a new one To check valve opening temperature suspend the thermostat and an accurate thermometer A in a container of water Place the container over a source of heat and gradually raise the temperature of the water while stirring the water gently Watch the valve As soon as the valve starts to open note the temperature l f it is out of the specified range replace the thermostat Thermostat Valve Opening Temperature 69 5 72 5 C 157 162T http mototh com
156. ly the brake and hold it B 3 Close the bleed valve C 4 Release the brake D NOTE O The fluid level must be checked often during the changing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line Remove the clear plastic hose Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 8 kg m 69 in lb After changing the fluid check the brake for good braking power no brake drag and no fluid leakage l f necessary bleed the air from the lines Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power AWARNING Be sure to bleed the air from the brake whenever brake lever or pedal action feels soft or spongy after the brake fluid is changed or whenever a brake line fitting has been loosened for any reason N O T E O The procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake Remove th
157. ly with a damp cloth Front Master Cylinder Removal Pull back the dust cover and remove the banjo bolt A to disconnect the upper brake hose from the master cylinder see Brake Hose Removal Installation Notes When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Remove the clamp bolts B and take off the master cylinder C as an assembly with the reservoir and brake lever Front Master Cylinder Installation Notes The master cylinder clamp must be installed with the arrow mark A upward OTighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Front Master Cylinders Clamp Bolts 8 8 N m 0 9 kg m 78 in lb Replace the washers that are on each side of the hose fitting with new ones Torque the brake hose banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kg m 18 0 ft lb Bleed the brake line see Bleeding the Brake Line Check the brake for good braking power no brake drag and no fluid leakage Rear Master Cylinder Removal Remove the reservoir guard and the reservoir mounting bolt A Remove the cotter pin F Pull off the joint pin B NOTE O Pull off the joint pin while pressing down the brake pedal Remove the brake hose banjo bolt C see Brake Hose Removal Installation Notes When rem
158. m Remove the following Engine Breather Hose lower end KLX250D Regulator KLX250D Seat Fuel Tank For KLX250D remove the carburetor A to the left For KLX250E remove the carburetor A upward Pull the hoses off the carburetor Stuff pieces of lint free clean cloth into the carburetor holder and the air cleaner duct to keep dirt out of the engine and air cleaner AWARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive engine wear and possibly engine damage will occur Installation Notes When installing the carburetor into the carburetor holder fit the ridge A into the notch B Route the air vent and overflow hoses properly see Cable Wire and Hose Routing in the General Information chapter CAUTION Always keep the hoses free of obstruction and make sure they do not get pinched by the chain or shock absorber Check fuel leakage from the carburetor AWARNING Fuel spilled from the carburetor is hazardous Adjust Throttle Grip Free Play Idle Speed FUEL SYSTEM 2 9 http mototh com 2 10 FUEL SYSTEM Disassembly I Assembly Notes AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine KLX250D or turn the ignition switch OFF KLX2S0E Do not smoke Make sure the area is we
159. m 18 0 ft lb http mototh com SUSPENSION 12 17 Inner Tube Inspection Visually inspect the inner tube and repair any damage Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage l f the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Guide Bushing Inspection Visually inspect the guide bushings A and replace them if necessary Dust Seal Inspection Inspect the dust seals A for any signs of deterioration or damage Replace it if necessary Spring Tension Since a spring becomes shorter as it weakens check its free length to determine its condition l f the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Fork Spring Free Length A Standard 460 5 mm Service Limit 451 mm http mototh com 12 18 S
160. mage If necessary replace them Take out the stand or other suitable means under the engine and slowly compress the front forks all the way http mototh com 12 6 SUSPENSION In this position put the oil level gauge on the tube and measure the distance from the top of the inner tube to the oil level Special Tool Fork Oil Level Gauge 57001 1290 A Oil Level fully compressed without spring Standard 127 2 mm Adjust the oil level as required within the specification using one of the following oils Recommended Oil KAYABA 01 or SAE5W Fork Oil Change Remove the drain screw A from the lower end of the outer tube on each side Compress the front fork a few times to pump out the oil Using the jack under the frame stabilize the motorcycle Place a stand or block under the engine so that the front wheel is raised off the ground Apply a non permanent locking agent to the drain screws and install them Remove the top plugs from the top of the fork tubes Pull out the spacer D spring seat C and spring E Check the O rings B of the top plugs A for damage If necessary replace them Special Tool Jack 57001 1238 Pour in the type and amount of fork oil specified Recommended Oil KAYABA 01 or SAE 5W Front Fork Oil Capacity 633 4 mL Check the oil level see Oil Level Adjustment l f the oil is above or below the specified level remove or add oil
161. me anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the tank Remove the fuel tank and drain it Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits Pour the solvent out of the tank Remove the fuel tap from the tank by taking out the bolts with nylon flat washers Clean the fuel tap filter screens in a high flash point solvent Pour high flash point solvent through the tap in all lever positions Dry the tank and tap with compressed air Install the tap in the tank Install the fuel tank Fuel Tap Removal Remove the fuel tank and drain it Remove the mounting bolts and take out the fuel tap Fuel Tap Installation Notes Be sure the O ring is in good condition to prevent leaks Be sure to clamp the fuel hose to the tap to prevent leaks Do not use steel washers in place of the nylon washers Fuel Tap Inspection Remove the fuel tap Check the fuel tap filter screens B for any breaks or deterioration A O ring C Gasket B Filter Screens D Nylon Washer l f the fuel tap screens have any breaks or are deteriorated they may allow dirt to reach the carburetor causing poor running Replace the fuel tap l f the fuel tap leaks or allows fuel to flow when it is at ON or RES position without engine running replace the dam
162. mixture in the combustion chamber To do this effectively and at the proper time the correct spark plug must be used and the spark plug must be kept clean and the gap adjusted Tests have shown the plug listed in the General Information chapter to be the best plug for general use Since spark plug requirements change with the ignition and carburetion adjustments and with riding conditions whether or not a spark plug of the correct heat range is used should be determined by removing and inspecting the plug Terminal A Insulator B Cement C Gasket D Center Electrode E Gap 0 7 0 8 mm F Reach G Side Electrode H http mototh com When a plug of the correct heat range is being usea the electrodes will stay hot enough to keep all the carbon burned off but cool enough to keep from damaging the engine and the plug itself This temperature is about 400 800 C 750 1450 F and can be judged by noting the condition and color of the ceramic insulator around the center electrode If the ceramic is clean and of a light brown color the plug is operating at the right temperature A spark plug for higher operating temperatures is used for racing Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a colder plug If a spark plug with too cool a heat range is used that is a cold plug that cools itself too well the plug will stay too cool to burn off the carbon and
163. moothly and returns by spring tension l f the throttle valve does not move smoothly replace the carburetor Disassemble and clean the carburetor Check that the O rings on the float bowl and the diaphragm on the vacuum piston are in good condition l f any of the O ring or diaphragm are not in good condition replace them Check the plastic tip A of the float valve needle B It should be smooth without any grooves scratches or tears l f the plastic tip is damaged C replace the needle Push the rod D in the valve needle and then release it l f it does not spring out replace the needle Check the tapered portion A of the pilot screw B for wear or damage l f the pilot screw is worn or damaged on the tapered portion it will prevent the engine from idling smoothly Replace it http mototh com 2 12 FUEL SYSTEM Air Cleaner Housing Removal Set the jack under the frame Special Tool Jack 57001 1238 Remove Seat Side Covers Silencer Rear Fender Front Rear Fender Flap Igniter Engine Breather Hose Lower End A Pull the air cleaner duct out of the carburetor Remove the air cleaner housing mounting bolt A Remove the air cleaner housing Housing Installation Notes Route harness lead and hose tube in accordance with the Cable Wire and Hose Routing in the General Information chapter Element Removal Remove the seat Take off the air cl
164. moval Remove the caliper cover Loosen the pad bolts Unscrew the caliper mounting bolts Detach the caliper from the disc Take the piston side pad A out of the caliper holder B Push the caliper holder toward the piston and then remove another pad C from the caliper holder shafts Installation Notes Push the caliper pistons in by hand as far as they will go Install the anti rattle spring in place Install the piston side pad first and then another pad Tighten the brake pad bolts Torque Brake Pad Bolt 18 N m 1 8 kg m 13 ft lb Install the caliper see Caliper Installation Notes AWARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first application of the lever or pedal if this is not done Inspection Check the lining thickness and condition of the pads in each caliper l f either pad is damaged replace both pads in the caliper as a set l f the lining thickness A of either pad is less than the service limit B replace both pads in the caliper as a set Lining Thickness Front Rear Standard 3 8 mm 4 7 mm Secretive Limit 1 mm 1 mm http mototh com Master Cylinder BRAKES 11 13 CAUTION Brake fluid quickly ruins painted or plastic surfaces any spilled fluid should be completely wiped up immediate
165. moval 15 11 Stator Installation Notes 15 11 Inspection 15 11 Charging System 15 12 Regulator Inspection 15 12 Ignition System 15 13 Safety Instructions 15 13 Ignition Coil Removal 15 13 Ignition Coil Inspection 15 13 Measuring coil resistance 15 13 Spark Plug Cleaning and Inspection 15 14 Spark Plug Gap Inspection 15 14 CDI Unit Removal 15 14 CDI Unit Inspection 15 15 Pickup Coil Inspection 15 16 Stator Coil Inspection 15 16 Interlock Diode Unit Inspection KLX250E 15 16 Meter KLX250E 15 20 Removal 15 20 Meter Mounting Inspection 15 20 Bulb Replacement Notes 15 20 Thermostatic Fan Switch Inspection 15 22 Water Temperature Sensor inspection 15 22 Lighting System 15 23 Headlight Beam Adjustment 15 23 Headlight Bulb Replacement Notes 15 23 Headlight Unit Removal Installation Note 15 23 Taillight Bulb Replacement Notes 15 23 Headlight Lens Removal Installation Note 15 24 Turn Signal Inspection KLX250E 15 24 Condenser Inspection KLX250E 15 24 Radiator Fan KLX250E 15 25 Radiator Fan Removal 15 25 Fan System Circuit Inspection 15 25 Fan Motor Inspection 15 25 Fan Relay Inspection 15 25 Coolant Temperature Warning System KLX250E 15 27 Warning System Inspection 15 27 Warning Light Operation Inspection 15 27 Switches KLX250E 15 29 Brake Light Timing Inspection 15 29 Brake Light Timing Adjustment 15 29 Switch Inspection 15 29 http mototh com 15 2 ELECTRICAL SYSTEM Explod
166. moval and disassembly clean the motorcycle Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the motorcycle This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a cross pattern This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 5 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or instal
167. movement is not free after lubricating if the cable is frayed or if the cable housing is kinked replace the cable Points Lubricate with Grease Throttle Inner Cable Lower Ends A Choke Cable Lower End Clutch Cable Ends A Speedometer or Odometer Gear Housing and Inner Cable Grease the lower part of the Inner cable sparingly http mototh com 16 10 APPENDIX Unit Conversion Table Prefixes for Units Prefix Symbol Power mega M x 1 000 000 kilo k x 1 000 centi c x0 01 milli m x 0 001 micro M x 0 000001 Units of Mass kg X 2 205 9 X 0 03527 lb oz Units of Length km x 0 6214 m x 3 281 mm x 0 03937 Units of Torqi j e N m x 0 1020 N m x 0 7376 N m X 8 851 kg m x 9 807 kg m X 7 233 kg m x 86 80 mile ft in kg m ft lb in lb N m ft lb in lb Units of Volume L x 0 2642 gal US L x 0 2200 gal imp L X 1 057 qt US L X 0 8799 qt imp L X 2 113 pint US L X 1 816 pint imp mL X 0 03381 oz US ml_ X 0 02816 oz imp mL X 0 06102 cu in Units of Force N X 0 1020 kg N X 0 2248 lb kg X 9 807 N kg X 2 205 lb Units of Pressure kPa X 0 01020 kg cm 2 kPa X 0 1450 psi kPa X 0 7501 cm Hg kg cm 2 X 98 07 kPa kg cm 2 X 14 22 psi cm Hg X 1 333 kPa Units of Temperature http
168. n or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Magneto flywheel loose Camshaft chain tensioner trouble Camshaft chains sprockets guides worn Balancer gear worn or chipped Balancer position maladjusted Balancer mechanism springs weak or broken Balancer bearings worn Abnormal Drive Train Noise Clutch noise Clutch rubber damper weak or damaged Clutch housing friction plate clearance excessive Clutch housing gear primary gear worn Metal chip jammed in clutch housing gear teeth Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive chain noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket s worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Master cylinder damaged Other noise Brackets nuts bolts etc not properly mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high http mototh com APPENDIX 16
169. n compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board Additionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the carburetion system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere Instead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions
170. n the axle nut B Rotate the chain adjuster C at each end of the swing arm to obtain the specified chain slack Check the wheel alignment Tighten the axle nut Torque Axle Nut 98 N m 10 kg m 72 ft lb Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary Insert a new cotter pin through the axle and spread its ends AWARNING If the axle nut is not securely tightened and the cotter pin is not installed an unsafe riding condition may result Check the rear brake for weak braking power and brake drag see the Brakes chapter KLX250E Remove the cotter pin and loosen the axle nut A Loosen the left and right chain adjuster locknuts D If the chain is too tight back out the left and right chain adjusting nuts C evenly and push the wheel forward until the chain is too loose If the chain is too loose turn both chain adjusting nuts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the left chain adjuster should align with the same swingarm mark F as the right chain adjuster notch aligns with http mototh com FINAL DRIVE 10 5 Tighten the axle nut loosely and tighten the left and right adjusting nuts slightly Take care not to change the adjustment during the adjusting nut tightening Tighten the both chain adjuster locknuts securely T
171. n the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser Continued on next page http mototh com NOTE o The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary or rendering inoperative of devices or elements of design in order to perform maint
172. n the front fork legs is atmospheric pressure The air pressure in the front legs increases as the fork heats up so the fork action will get stiffer as vehicle operation progresses Park the vehicle on level ground Remove the screws A at the top of the front fork top plugs to let the air pressure equalize to atmospheric pressure Compression Damping Adjustment Euro Clean the bottom of the outer tubes Remove the caps on the bottom of the outer tubes To adjust compression damping turn the adjuster A on the front fork cylinder valve with the blade of a screwdriver until you feel a click Adjust the compression damping to suit your preference under special conditions Compression Damping Adjuster Setting Standard 14th clicks CAUTION The left and right fork legs must have the same shock damping Put the caps into the bottom of the outer tubes A Seated positions adjuster turned fully clockwise Oil Level Adjustment Using the jack under the frame stabilize the motorcycle Place a stand or block under the engine so that the front wheel is raised off the ground Remove the top plugs from the top of the fork tubes Special Tool Jack 57001 1238 AWARNING The top plugs are under extreme spring pressure Take care when removing the top bolts Wear eye and face protection Pull out the spacer D spring seat C and spring E Check the O rings B of the top plugs A for da
173. ndard Service Limit Cylinder Piston Cylinder inside diameter 78 000 78 012 mm 78 07 mm Piston diameter 77 950 77 965 mm 77 80 mm Piston cylinder clearance 0 035 0 062 mm Piston ring groove clearance 0 035 0 062 mm Top 0 03 0 07 mm 0 17 mm Second 0 03 0 07 mm 1 12 mm Oil 2 01 2 03 mm 2 11 mm Piston ring groove width Top 0 97 0 99 mm 0 90 mm Second 0 97 0 99 mm 0 90 mm Piston ring end gap Top 0 20 0 35 mm 0 7 mm Second 0 20 0 45 mm 0 7 mm http mototh com Final Drive 1 Specifications Item Standard Service Limit Drive Chain Standard Chain Make DAI DO Type D I D 520VL 2 Endless Link 110 Chain slack 50 60 mm 5 0 6 5 mm 20 link length 3 1 7 5 318 2 mm 323 mm Sprockets Engine sprocket diameter 60 98 6 1 1 8 mm 14 T 60 6 mm Rear sprocket diameter 242 71 243 21 mm 50 T 242 4 mm Rear sprocket warp 0 4 mm or less 0 5 mm http mototh com 14 Brakes Specifications Item Standard Service Limit Brake Lever Brake Pedal Brake lever free play Pedal free play Adjustbale to suit rider Non adjustable Brake Fluid Grade Brand recommended 315AA D 0 T 3 or 418AA D O T 4 Shown below Brake Pads Lining thickness Front Rear 3 8 mm 6 4 mm 1 mm 1 mm Brake Disc Thickness Front Rear Runout 2 85 mm 3 15 mm 4 35 mm 4 65 mm 0 12 mm or less 2 5 mm 3 8 mm 0 3 mm Recommended
174. ng coil resistance 0 4 1 1 Q Regulator rectifier resistance in the text Ignition System Pickup coil air gap 0 4 0 6 mm Pickup coil resistance 180 280 O Ignition coil 3 needle arcing dis tance 7 mm or more Primary winding re sistance 0 2Q 15 Secondary winding resistance 6 3 kQ 15 Spark plug Spark plug gap 0 7 0 8 mm Spark plug cap resistance 3 75 6 25 kQ CDI unit resistance in the text AC Lighting System Alternator type Three phase AC Lighting coil resistance 0 4 1 1 Q Regulator resistance in the text Capacity of headlight capacitor 3700 5700 uF Switch and Sensor Rear brake light switch timing ON after about 10 mm pedal travel Fan switch connections Rising temperature From OFF to ON 94 100 C 201 212 F F ailing temperature From On to OFF 90 93 C 194 199 F ON Less than 0 5 O OFF More than 1 MO Coolant temperature switch connections F ising temperature From OFF to ON 107 113 C 225 236 F Falling temperature From ON to OFF 103 106 C 217 223 F ON Less than 0 5 O OFF More than 1 MQ http mototh com 17 14 SUPPLEMENT FOR 1994 MODEL http mototh com K L X 2 5 0 G W i r i n g D i a g r a m http mototh com SUPPLEMENT FOR 1994 MODEL 17 15 http mototh com SUPPLEMENT FOR 1994 MODEL 17 17 Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery te
175. nit Check http mototh com 15 18 ELECTRICAL SYSTEM Headlight Circuit Wiring Diagram Europe Model KLX250E Headlight Circuit Wiring Diagram Australia Model KLX250E http mototh com ELECTRICAL SYSTEM 15 19 Turn Signal Light Circuit Wiring Diagram KLX250E http mototh com 15 20 ELECTRICAL SYSTEM Meter KLX250E Removal Remove the headlight unit Disconnect the meter lead connectors A Disconnect the speedometer cable upper end B Unscrew the mounting nuts A and remove the meter unit B CAUTION Place the meter or gauge so that the face is up If a meter or gauge is left upside down or sideways for any length of time it will malfunction Meter Mounting Inspection Check to see that the rubber dampers A in the meter mounting bracket are in good condition They should not be hard or cracked Replace any damaged rubber dampers with new ones Check to see that all meter mounting nuts are tightened securely Tighten any loose fasteners Bulb Replacement Notes To remove the wedge base type bulbs indicator and illumination pull out the bulb sockets and pull the bulbs off the sockets CAUTION Do not use bulbs rated for greater wattage than the specified value as the meter or gauge panel could become warped by excessive heat radiated from the bulbs http mototh com ELECTRICAL SYSTEM 15 21 Ignition Circuit KLX250D 1 Engine Stop Switch 2 Ignition Coi
176. nt Headlight Type Semi sealed beam Bulb 12 V 60 55 W quartz halogen Tail brake light 12 V 5 21 W Alternator Type Three phase AC Rated output 14 5 A 14 V 7000 r min rpm Specifications subject to change without notice and may not apply to every country AR Austria Model IT Italy Model AS Australia Model NR Norway Model FG Germany Model http mototh com 1 10 GENERAL INFORMATION Periodic Maintenance Chart KLX250D The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition ENGINE Clutch adjust Clutch and friction plates check Throttle cables adjust Spark plug clean gap Valve clearance check Air cleaner element clean Air cleaner element replace Carburetor inspect adjust Spark arrester US clean Oil filter replace Engine oil change Engine sprocket check Coolant change Radiator hoses connections check CHASSIS Brake adjustment check Brake pad wear check Brake fluid level check Brake fluid change Brake master cylinder cup and dust seal replace Brake caliper piston seal and dust seal replace Brake hose replace Spoke tightness and rim runout check Drive chain adjust Drive chain lubricate Drive chain wear check Chain slipper and guide check Front fork inspect clean Front fork oil
177. nts exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Chain 20 Link Length Standard 317 5 318 2 mm Service Limit 323 mm AWARNING If the drive chain wear exceeds the service limit replace the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprockets could sag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Drive Chain KLX250D KLX250E Make DAI DO ENUMA Type DID520DS 6 EK520LV 0 Link 110 106 Drive Chain Lubrication If the chain appears especially dirty it should be cleaned before lubrication with high flash point solvent Apply oil A to the sides of the rollers so that oil will penetrate to the rollers and bushings Wipe off any excess oil http mototh com FINAL DRIVE 10 7 Drive Chain Removal Remove the engine sprocket cover Remove the clip from the master link using pliers and free the drive chain from the rear sprocket Drive Chain Installation Notes Installation is the reverse of removal Fit the drive chain back onto the sprockets with the ends at the rear sprocket Install the master link from the frame side Install the clip A so that the closed end of the U pointed in the direction of chain rotation B Adjust the drive chain slack see Drive Chain Slack Adjustment Che
178. ollowing OChip off the old gasket from the mating surface of the crankcase halves and clean off the crankcase with a high flash point solvent After cleaning apply engine oil to the transmission gears shift drum shift forks and so on OBe sure to replace any oil seal removed with a new one Press in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the crankcase O Apply high temperature grease to the oil seal lips O Press in the ball bearings using the bearing driver set until the bearing is bottomed Special Tool Bearing Driver Set 57001 1129 CAUTION Do not remove the bearings unless it is necessary Removal may damage them Install the bearings for the crankshaft in the right and left crankcase so that their sealed sides face toward the oil seal side Olf the crankshaft bearings stay on the crankshaft when splitting the crankcase remove the bearings from the crankshaft and reinstall them in the crankcase and then assemble the crankcase see Crankshaft Removal and Installation Notes T u rn the crankshaft to BDC and install the crankshaft jig A between the crankshaft flywheels opposite the connecting rod big end to protect flywheel alignment as shown O If the crankshaft has been removed from the crankcase install the jig between the crankshaft flywheels before pressing the crankshaft into the left crankshaft half Special Tool Crankshaft Jig 57001 1174 A
179. om 9 2 WHEELS TIRES Exploded View KLX250D E T1 1 5 N m 0 15 kg m 13 in lb T2 88 N m 9 0 kg m 65 ft lb T3 98 N m 10 0 kg m 72 ft lb http mototh com WHEELS TIRES 9 3 Specifications Item Standard Service Limit Rim runout Axial Radial Axle runout 100 mm Wheel balance Balance weights 0 5mm or less 0 8 mm or less 0 10 mm or less 10 g or less 10 g 20 g 30 g 2 mm 2 mm 0 2 mm Tire tread depth KLX250D Front Rear KLX250E Front Rear 10 8 mm 16 2 mm 8 3 mm 11 8 mm 2 mm 2 mm 2 mm 2 mm TTTiiirrreee aaaiiirrr ppprrreeessssssuuurrreee KKKLLLXXX222555000DDD KKKLLLXXX222555000EEE Load Air Pressure when cold Front 100kPa 1 0 kg cm2 14psi Rear 100 kPa 1 0 kg cm2 14 psi Front 150 kPa 1 5 kg cm2 21 psi RRReeeaaarrr Up to 97 5 kg 215 1b 150 kPa 1 5 kg cm2 21 psi 97 5 1 8 1 kg 215 399 lb 175 kPa 1 75 kg cm2 25 psi SSStttaaannndddaaarrrddd tttiiirrreee KKKLLLXXX222555000DDD KKKLLLXXX222555000EEE FFFrrrooonnnttt Make type DUNLOP D752F Tube AS US DUNLOP K490 Tube Size 8 0 1 0 0 2 1 51 M RRReeeaaarrr Make type DUNLOP D752 Tube AS US DUNLOP K695 Tube Size 1 0 0 1 0 0 18 59M FFFrrrooonnnttt Make type DUNLOP D603 Size 3 00 21 51 P RRReeeaaarrr Make type DUNLOP D603 Size 4 6 0 18 63P AS Australia Model Special Tools Inside Circlip Pliers 57001 143 Bead Breaker Assembly
180. on the motorcycle upright so that the coolant may be drained easily Place a container under the water pump A Drain the coolant from the radiator and engine by removing the drain plug B at the bottom of the water pump Remove the left side cover Remove the reservoir tank B mounting bolt A and take off the reservoir tank from the frame Unscrew the cap C and pour the coolant into a container Inspect the old coolant for visual evidence of corrosion and abnormal smell see Coolant Deterioration Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the manufacturer s instructions Soft or distilled water must be used with the antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system COOLING SYSTEM 3 7 http mototh com 3 8 COOLING SYSTEM Coolant Type Permanent type antifreeze tor aluminum engines and radiators Color Green Mixed ratio Soft water 50 coolant 50 Freezing point 35 C 31 F Total amount 1 6L Install the reservoir tank on the frame Install the drain plug Always replace the gasket with a new one if it is damaged Tighten the drain plug Torque Drain Plug 25 N m 2 5 kg m 18 0 ft lb Fill the radiator up to the b
181. ont Rear Rear Brake Push Rod Locknut Brake Pad Bolts Front Rear 25 1 5 5 9 8 8 7 8 9 8 23 25 17 18 2 5 0 15 0 6 0 9 0 8 1 0 2 3 2 5 1 75 1 8 18 0 13 in lb 52 in lb 78 in lb 69 in lb 87 in lb 16 5 18 0 12 7 13 Suspension Upside Down Type Front Top Plug Front Fork Upper Clamp Bolts Front Fork Lower Clamp Bolts Front Fork Oil Drain Screw Push Rod Nut Front Fork Cylinder Valve ASSY Rear Shock Absorber Upper Mounting Bolt Rear Shock Absorber Lower Mounting Nut Swing Arm Pivot Shaft Nut Rocker Arm Pivot Nut Tie Rod Mounting Nuts Upper Lower 29 20 23 15 54 39 39 88 3 0 2 0 2 3 1 5 5 5 4 0 4 0 9 0 98 81 22 14 5 16 5 11 40 29 29 65 10 0 8 3 L 72 60 Steering Handlebar Clamp Bolts Steering Stem Head Nut 25 44 2 5 4 5 18 0 33 S http mototh com FFFaaasssttteeennneeerrr Torque RRReeem m maaarrrkkksss N m kg m ft lb Front Fork Upper Clamp Bolts Front Fork Lower Clamp Bolts Steering Stem Locknut 20 25 Hand Tighten about 3 9 2 0 2 5 Hand Tighten about 0 4 14 5 18 0 Hand Tighten about 35 in lb Electrical System Spark Plug Magneto Flywheel Bolt Stator Coil Mounting Bolts Pickup Coil Mounting Screws 14 120 5 9 2 5 1 4 12 0 6 0 25 10 87 52 in lb 22 in lb The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bo
182. ormation chapter Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Check idle speed F o r KLX250D adjust as needed KLX250E Idle Speed 1300 100 r min rpm F o r KLX250E if the idle speed is out of the specified range adjust it Idle Speed Adjustment Start the engine and warm it up thoroughly First turn in the pilot screw A until it seats lightly and back it out to the specifications see Service Data For KLX250D turn the idle adjusting screw B to obtain the desired idle speed If no idle is preferred turn out the screw until the engine stops For KLX250E turn the adjusting screw B until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is as desired or within the specified range Readjust if necessary l f the engine idle is still not stable adjust the pilot screw to obtain the proper idle speed using the pilot screw adjuster A Special Tool Pilot Screw Adjuster A 57001 1239 OTurn in the pilot screw fully but not tightly and then back it out the specified turns Pilot Screw Setting KLX250D 1 1 2 1 4 KLX250E 1 7 8 1 4 IT NL 2 3 8 AR ST 1 1 4 Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition To avoid a serious burn never touch a hot engine or an exhaust pipe during
183. ottom of the radiator filler neck with coolant and install the cap turning it clockwise about 1 4 turn A Coolant Level NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator O The radiator cap must be installed in two steps First turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way Check the cooling system for leaks Fill the reservoir tank up to the FULL mark with coolant and install the cap Air Bleeding Before putting the motorcycle into operation any air trapped in the cooling system must be removed as follows Check the cooling system for leaks Start the engine warm it up thoroughly and then stop it Check the coolant level in the reservoir tank after the engine cools down l f the coolant level is low add coolant up to the Full mark http mototh com COOLING SYSTEM 3 9 Coolant Leak Inspection Any time the system slowly loses coolant inspect for leaks Visually check the water pump drainage outlet passage A for coolant leaks l f the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Replace the mechanical seal as a unit with a new one CAUTION Whenever the mechanical seal is replaced the oil seal and the ball bearing must be replaced with new ones too l f there are no apparent leaks pressure test the cooling system Cooling System Pressure Test
184. ound the valve guide to about 120 150 C 248 302 F Special Tool Valve Guide Arbor 04 5 57001 1331 CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing extensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage Do not grind the valve stem end to repair it or to permit additional valve clearance If the valve end is ground the lifter may contact the spring retainer and or split keepers during operation allowing the keeper to loosen Consequently the valve may drop into the engine causing serious damage http mototh com 4 18 ENGINE TOP END VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1 Measure the clearance with engine cold 2 Check present shim size 3 Match clearance in vertical column with present shim size in horizontal column 4 Install the shim specified where the lines intersect This shim will give the proper clearance Example Present shim is 2 55 mm Measured clearance is 0 42 mm Replace 2 55 mm shim with 2 75 mm shim 5 Remeasure the valve clearance and readjust if necessary CAUTION Be sure to remeasure the clearance after selecting a shim according to the table The clearance can be out of the specified range because of the shim tolerance A Cam C Shim B Valve Lifter NOTE Olf the valve clearance is smaller larger than the standard select a thinner thicker s
185. oval Remove the cylinder head Remove the valve lifter and the shim Use the valve spring compressor assembly and the adapter to press down the valve spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 22 57001 1202 Remove Spring Retainer Outer Valve Spring Inner Valve Spring Remove the valve Installation Replace the oil seal C with a new one Apply a thin coat of molybdenum disulfide grease to the valve stem A Check the following 1 Valve moves smoothly up and down in the guide 2 Valve seats properly in the valve seat Install the inner valve spring D and the outer valve spring E with their closed coil ends toward the spring seat B Put the spring retainer F on the springs and fit the split keepers G between the retainer and valve stem while compressing the valve spring Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 22 57001 1202 Install the shim H with its marked side toward the valve lifter NOTE OApply high temperature grease to the shim or the spring retainer to keep the shim in place during camshaft installation Guide Removal Remove the valve Remove the oil seal Remove the spring seat Hammer lightly on the valve guide arbor A to remove the guide from the top of the head http mototh com NOTE O Heat the area ar
186. ove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution This will prevent damage or deterioration of the parts The carburetor body has plastic parts that cannot be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged http mototh com FUEL SYSTEM 2 11 Disassemble the carburetor Immerse all the metal parts in a carburetor cleaning solution Rinse the parts in water When the parts are clean dry them with compressed air Blow through the air and fuel passages with compressed air Assemble the carburetor Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine KLX250D or turn the ignition switch OFF KLX250E Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the carburetor Before disassembling the carburetor check the fuel level see Fuel Level Inspection l f the fuel level is incorrect inspect the rest of the carburetor before correcting it T u r n the throttle cable pulley to check that the throttle butterfly valve moves s
187. ove width 6 05 6 20 mm 6 25 mm Special Tool Outside Circlip Pliers 57001 144 Bearing Puller 57001 135 Bearing Puller Adapter 57001 136 Bearing Driver Set 57001 1129 Crankshaft J ig 57001 1174 Sealant Kawasaki Bond Liquid Gasket Silver 92104 002 Kawasaki Bond Silicone Sealant 56019 120 http mototh com CRANKSHAFT TRANSMISSION 8 5 Crankcase Splitting Remove the engine see Engine Removal Installation chapter Set the engine on a clean surface while parts are being removed Remove Cylinder Head Cover Magneto Cover Right Engine Cover Clutch Primary Gear Oil Pump and Oil Pump Drive Gear Kick Idle Gear and Circlips Kick Shaft Assembly Camshaft Chain Tensioner Camshaft chain Tension Spring Camshafts Magneto Flywheel External Shift Mechanism Cover External Shift Mechanism Main Oil Pipe Cylinder Head Cylinder Piston Camshaft Chain Camshaft Chain Tension Guide Remove the output shaft sleeve A and O ring B Remove the crankcase bolts A Ply the points A in the figure with a screwdriver to split the crankcase halves apart evenly There are two knock pins on the crankcase mating surface Pull off the right crankcase half Remove the transmission from the left crankcase half Remove the crankshaft from the left crankcase half using a press http mototh com 8 6 CRANKSHAFT TRANSMISSION Assembly Before fitting the right case on the left case note the f
188. oving the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum http mototh com 11 14 BRAKES Take off the master cylinder mounting screws D and remove the master cylinder E with the reservoir Remove the reservoir cap and pour the brake fluid into a container I Remove the reservoir and its hose from the master cylinder Rear Master Cylinder Installation Notes Replace the cotter pin with a new one Replace the washers that are on each side of the hose fitting with new ones Torque the following Torque Brake Hose Banjo Bolt 25 N m 2 5 kg m 18 0 ft lb Bleed the brake line see Bleeding the Brake Line Check the brake for good braking power no brake drag and no fluid leakage Check the brake pedal position Front Master Cylinder Disassembly Remove the front master cylinder Remove the reservoir cap and diaphragm and pour the brake fluid into a container Remove the locknut and pivot bolt and remove the brake lever Push the dust cover A out of place and remove the circlip B Special Tool Inside Circlip Pliers 57001 143 Remove the washer C pull out the piston D secondary cup E primary cup F and return spring G CAUTION Do not remove the secondary cup from the piston since removal will damage it Rear Master Cylinder Disassembly Remove the rear master cylinder Slide the dus
189. ox cover Modifications to the muffler s or air intake system by cutting drilling or other means if such modifications result in increased noise levels http mototh com
190. pect the shift forks and replace any fork that is bent A A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 http mototh com CRANKSHAFT TRANSMISSION 8 13 Shift Fork I Gear Groove Wear Measure the thickness of the shift fork ears A and measure the width B of the shift fork grooves in the transmission gears If the thickness of the shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard 4 4 4 5 mm Service Limit 4 3 mm i f the gear shift fork groove is worn past the service limit the gear must be replaced Gear Shift Fork Groove Width Standard 4 55 4 65 mm Service Limit 4 8 mm Shift Fork Guide Pin Shift Drum Groove Wear Measure the diameter A of each shift fork guide pin and measure the width B of each shift drum groove l f the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 900 6 000 mm Service Limit 5 80 mm l f any shift drum groove is worn past the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm Service Limit 6 25 mm Gear Damage Visually inspect the gear teeth on the transmission gears kRepair lightly damaged gear teeth with an oilstone The gear must be replaced if the teeth are badly damaged A t
191. pension Front Fork Clamp Bolts Front Fender Mounting Bolts Swingarm Pivot Shaft Nut Uni trak Link Nuts Rear Shock Absorber Bolts Steering Stem Head Nut Handlebar Clamp Bolts Engine Engine Mounting Bolts Nuts Cylinder Head Cover Bolts Shift Pedal Bolt Exhaust Pipe Holder Nuts Muffler Connecting Clamp Bolts Muffler Bolt and Nut Clutch Lever Pivot Nut Others Side Stand Nut Footpeg Bolts Nuts http mototh com General Lubrication APPENDIX 16 9 Lubrication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Lubricate the points listed below with indicated lubricant in accord ance with the Periodic Maintenance Chart NOTE O Whenever the vehicle has been operated under wet or rainy condi tions or especially after using a high pressure spray water perform the general lubrication Chain Lubricate with Heavy Oil Pivots Lubricate with Motor Oil Side Stand Clutch Lever Brake Pedal Rear Brake Rod Joint Footpegs Cables Lubricate with Cable Lubricant Throttle Cables Clutch Cable Choke Cable Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a pressure cable luber A with an aerosol cable lubricant B Special Tool Pressure Cable Luber K56019 021 A W i t h the cable disconnected at both ends the cable should move freely A within the cable housing l f cable
192. plit the crankcase Tap lightly up the balancer shaft with a rubber mallet to remove the balancer gear NOTE O To tight the balancer gear backlash two pieces of gear are used for the KLX250E balancer gear assembly OWhen disengaging mesh of the balancer gear assembly of the KLX250E from the driven gear install a suitable pin A about 3 mm diameter into straight hole B on the two balancer gears to keep gear alignment of the two ODo not disassemble the balancer gear assembly Hf the balancer gear assembly is damaged replace it as a unit Balancer Installation Notes Install the balancer gear on the balancer shaft aligning the punch mark A on the gear with the punch mark A on the shaft Put the balancer shaft into the crankcase aligning the punch mark A on the driven gear http mototh com CRANKSHAFT TRANSMISSION 8 11 Transmission Shaft Removal Split the crankcase see Crankcase Splitting Pull out the shift rod A and disengage the shift fork guide pins from the shift drum grooves Remove the shift drum B Remove the shift forks C from the transmission gears Take out the drive shaft D and output shaft E together with their gears meshed Shaft Installation Notes Hold the drive shaft A and output shaft B together with their gears meshed and fit them into the left crankcase half T o install the shift forks and shift drum see the Shift Drum and Fork Instal
193. plug Spark Plug Gap Inspection Measure the gap A with a wire type thickness gauge l f the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm CDI Unit Removal Remove Side Cover Disconnect the CDI unit lead B Remove the CDI unit A http mototh com ELECTRICAL SYSTEM 15 15 CDI Unit Inspection Set the hand tester to the x l k O range connect the tester to the terminals in the CDI unit lead and check the internal resistance following the table l f the readings do not correspond to the table replace the CDI unit Special Tool Hand Tester 57001 983 CAUTION Use only the Kawasaki Hand Tester for this test A tester other than the Kawasaki Hand Tester may show different readings Do not use a megger or a meter with a large capacity or the CDI unit will be damaged http mototh com 15 16 ELECTRICAL SYSTEM Pickup Coil Inspection Remove Side Covers Seat Disconnect the pickup coil lead connector Set the hand tester to the x10D range zero it and connect it to the pickup coil lead terminals in the connector l f there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Pickup Coil Resistance Standard 180 280 O Stator Coil Inspection Remove S
194. quare inch C degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center T degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating http mototh com Foreword This KLX300A Service Manual Supplement is designed to be used in conjunction with the KLX250D E Motorcycle Service Manual P N 99924 1165 01 The maintenance and repair procedures described in this supplement are only those that are unique to the KLX300A motorcycle Most service operations for these models remain identical to those described in the base Service Manual Complete and proper servicing of the KLX250D E motorcycle therefore requires both this supplement and the base Service Manual This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In ord
195. r interest for more efficient and convenient operation Indicates a procedural step or work to be done Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly http mototh com 1 Table of Contents General Information 2 Model Identification 2 General Specifications 3 Periodic Maintenance Chart 5 Torque and Locking Agent 7 Cables Wires and Hoses Piping Diagram 10 Fuel System 11 Specifications 11 Engine Top End 12 Specifications 12 Final Drive 13 Specifications 13 Brakes 14 Specifications 14 Suspension 15 Exploded View 15 Specifications 17 Electrical System 18 KLX300A Wiring Diagram 18 http mototh com 2 General Information Model Identification KLX300 A2 http mototh com 3 General Specifications Items KLX300 A2 Dimensions Overall length 2 115 mm Overall width 910 mm Overall height 1 220mm Wheelbase 1 435 mm Road clearance 320 mm Seat height 925 mm Dry weight 105 kg Curb we
196. rain plug for damage Replace the gasket with a new one if it is damaged After the oil has completely drained out install the drain plug with the gasket and tighten it Torque Drain Plug 15 N m 1 5 kg m 11 0 fl lb Fill the engine with a good quality engine oil Check the oil level Engine Oil Grade SE or SF class Viscosity SAE 10W 40 10W 50 20W 40 or 20W 50 Capacity 1 3L when filter is not removed 1 4L when filter is removed 1 5L when engine is completely dry Level Between upper and lower levels Oil Filter Removal Remove the oil filter cap Take out the oil filter A Oil Filter Installation Notes Check that the O ring A is in good condition l f it is damaged replace it with a new one A p p l y grease to the O ring to hold in its place Install the oil filter and cap http mototh com ENGINE LUBRICATION SYSTEM 6 7 Oil Pump and Relief Valve Relief Valve Removal Remove the right engine cover Remove the relief valve A from the oil passage in the right engine cover Relief Valve Installation Notes Apply a non permanent locking agent to the threads of the relief valve and tighten it Torque Relief Valve 15 N m 1 5 kg m 11 0 ft lb CAUTION Do not over apply a non permanent locking agent to the threads This may block the oil passage Oil Pump Removal Remove the right engine cover Remove the screws A and oil pump B
197. raise the motorcycle off the ground and put blocks under the front and rear tires to steady the motorcycle Special Tool Jack 57001 1238 D Pull out the swingarm pivot shaft A three quarters to avoid the swingarm from falling down This allows the pivot shaft to disengage from the engine Remove the engine brackets B and mounting bolts C Lift up the engine a little then tip it to the right Remove the engine to the right Installation Notes Installation is the reverse of removal Torque Swing Arm Pivot Shaft 88 N m 9 0 kg m 65 ft lb Engine Mounting Nuts 44 N m 4 5 kg m 33 ft lb Cylinder Head Bracket Bolts 8 A 29 N m 3 0 kg m 22 ft lb Bolts 10 B J 44 N m 4 5 kg m 33 ft lb Engine Bracket Bolts 44 N m 4 5 kg m 33 ft lb T o route the leads cable and hoses refer to the Cable Wire and Hose Routing in the General Information chapter T o install parts removed refer to the appropriate chapters Fill the engine with coolant see Coolant Change in the Cooling System chapter Fill the engine with engine oil see Engine Oil Change in the Engine Lubrication System chapter Adjust Throttle Cable Clutch Cable Drive Chain http mototh com CRANKSHAFT T R A N S M I S S I O N 8 1 Crankshaft Transmission Table of Contents Exploded View 8 2 Specifications 8 4 Crankcase 8 5 Splitting 8 5 Assembly 8 6 Crankshaft Connecting Rod 8 8 Removal 8 8
198. rance is still beyond the limit replace the cylinder head unit Camshaft Chain Wear Hold the chain taut with a force of about 5 kg in some manner and measure a 20 link length Since the chain may wear unevenly take measurements at several places l f any measurement exceeds the service limit replace the chain Also replace the camshaft sprockets and crankshaft when the chain is replaced Camshaft Chain 20 Link Length Standard 127 0 127 4 mm Service Limit 128 9 mm http mototh com ENGINE TOP END 4 11 KAWASAKI Automatic Compression Release KACR Due to the simplicity of the mechanism no periodic maintenance is needed There are only two symptoms of problems with the KACR mechanism compression is not released during starting and compression is released during running 1 If compression is not released during starting the weights are not returning to their rest position Remove the cylinder head cover Visually inspect the spring i f the spring is damaged deformed or missing replace it Remove the spring and move the weights back and forth l f the weights do not move smoothly all the way replace the exhaust camshaft 2 If compression is released while the engine is running the weights are not swinging out Remove the spring and move the weights back and forth l f the weights do not move easily from the retracted position replace the exhaust camshaft Weight 1 A Spring
199. reads S Tighten the fasteners following the specified sequence FFFaaasssttteeennneeerrr Torque RRReeem m maaarrrkkksss N m kg m ft lb Cooling System Water Pump Impeller Nut Coolant Drain Plug Thermostat Housing Cap Bolts Elbow Water Pipe Mounting Bolts Thermostatic Fan Switch Water Temperature Sensor 7 8 25 9 8 9 8 8 8 8 8 0 8 2 5 1 0 1 0 0 90 0 90 69 in lb 18 0 87 in lb 87 in lb 78 in lb 78 in lb Engine Top End Cylinder Head Cover Bolts Camshaft Cap Bolts Camshaft Sprocket Bolts Cylinder Head Bolts lt t gt 6 Cylinder Head Allen Bolts first torquing standard torquing Camshaft Chain Guide Mounting Bolt Camshaft Chain Guide Bracket Bolt Carburetor Holder Mounting Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Sub Tensioner Bolt Inspection Cap Rotor Cap 7 8 12 12 12 15 46 25 9 8 12 9 8 15 2 5 2 5 0 8 1 2 1 2 1 2 1 5 4 7 2 5 1 0 1 2 1 0 1 5 0 25 0 25 69 in lb 8 5 8 5 8 5 11 0 34 18 0 87 in lb 8 5 87 in lb 11 0 22 in lb 22 in lb S L S S S Engine Right Side Left Side Engine Oil Drain Plug Clutch Hub Nut Clutch Spring Bolts Shift Drum Cam Allen Bolt Return Spring Pin Primary Gear Nut Magneto Flywheel Bolt Kick Ratchet Guide Bolt External Shift Mechanism Cover Bolts and Nut External Shift Mechanism Cover Screw Position Lever Nut Neutral Switch KLX250E Exhaust Pipe Holder Nuts Clutch Cover Bolts Clutch Cable Mountin
200. refilled but the type and brand of the brake fluid that already is in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Mixing different types and brand of brake fluid lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Recommended Disc Brake Fluid Type D O T 4 Brand Castrol Girling Universal Castrol GT LMA Castrol Disc Brake Fluid Check Shock Premium Heavy Duty Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Furthermore the brake fluid should be changed whenever the brake line parts are removed to bleed the air quickly and completely NOTE O The procedure to change the front brake fluid is as follows O Changing the rear brake fluid is the same as for the front brake Level the brake fluid reservoir Remove the reservoir cap Remove the rubber cap on the bleed valve A Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container Fill the reservoir with fresh specified brake fluid http mototh com Change the brake fluid as follows O Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 App
201. rger 2 Battery 3 Standard Value 0 7 A http mototh com 17 18 SUPPLEMENT FOR 1994 MODEL Battery Standard Charge Time Chart 0 7 A x 5 10 h Regular Current Charge For Reference Determine battery condition after refreshing charge O Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below Criteria Judgement 12 6 V or higher Good 12 0 12 6 V or lower Charge insufficient Recharge 12 0 V or lower Unserviceable Replace http mototh com SUPPLEMENT FOR 1994 MODEL 17 19 Ignition System Refer to pp 15 23 noting the following Headlight Circuit Wiring Diagram KLX250G Turn Signal Light Circuit Wiring Diagram KLX250G http mototh com 17 20 SUPPLEMENT FOR 1994 MODEL Refer to pp 15 25 noting the following Radiator Fan Circuit 1 Radiator Fan Motor 5 Fuse 10 A 2 Fan Switch 6 Battery 3 Radiator 7 Main Fuse 20 A 4 Fan Relay http mototh com SUPPLEMENT FOR 1994 MODEL 17 21 Coolant Temperature Warning System Refer to pp 15 17 noting the following Coolant Temperature Warning Circuit 1 Ignition Switch 2 Coolant Temperature Warning Light 3 Coolant Temperature Sensor 4 Interlock Diode Unit 5 Diode 6 Neutral Switch 7 Main Fuse 20 A 8 Battery http mototh com MEMO http mototh com KLX300R Kawasaki Motorcycle Service Manual Supplemen
202. rily tighten the cylinder head bolts 8 mm Allen following the tightening sequence shown in the figure Torque Cylinder Head Bolts 8 mm Allen 15 N m 1 5 kg m 11 0 ft lb Retighten the cylinder head bolts 8 mm Allen following the tighten ing sequence shown in the figure Torque Cylinder Head Bolts 8 mm Allen 46 N m 4 7 kg m 34 ft lb Tighten the cylinder head bolts 6 mm Bolts Torque Cylinder Head Bolts 6 mm Bolts 12 N m 1 2 kg m 8 5 ft lb Warp Lay a straightedge across the lower surface of the head at several different points and measure warp by inserting a thickness gauge between the straightedge and head If warp exceeds the service limit repair the mating surface Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm http mototh com 4 14 ENGINE TOP END Cleaning Before installation blow the oil passages A clean with compressed air http mototh com ENGINE TOP END 4 15 Valves Clearance Inspection NOTE O If the engine is hot wait until the engine cools Valve clearance must be checked when the engine is cold room temperature Remove the cylinder head cover see Cylinder Head Cover Removal Unscrew the two caps A on the alternator cover Check the valve clearance when piston is at TDC Using a wrench on the crankshaft rotation bolt D turn the crankshaft counterclockwise while watching
203. rminal voltage Remove Seat IC Igniter Diode Disconnect the battery terminal leads CAUTION Be sure to disconnect the negative terminal lead first Measure the battery terminal voltage N O T E O Measure with a digital voltmeter which can be read one decimal place voltage l f the reading is below the specified refreshing charge is required Battery Terminal Voltage Standard 12 6 V or more 1 Battery 2 Sealing Cap OTerminal Voltage 11 5 12 6 V or less Standard Charge 0 7 A x 5 10 h see following chart Quick Charge 3 0 A x 1 0 h CAUTION If possible do not quick charge If the quick charge is done due to unavoidable circumstances do standard charge later on 1 Digital Voltmeter OTerminal Voltage 11 5 V or less Charging Method 0 7 A x 20 h N O T E O Raise the voltage initially 25 V as maximum and charge for about 5 minutes as a yardstick If ammeter shows no change in current after 5 minutes you need a new battery The current if it can flow into the battery tends to become excessive Adjust the voltage as often as possible to keep the current at standard value 0 7 A Refreshing Charge Remove the battery Refresh charge by following method according to the battery terminal voltage CAUTION This battery is sealed type Never remove sealing caps even at charging Never add water Charge with current and time as stated below 1 Battery Cha
204. rod nut A http mototh com 12 16 SUSPENSION OScrew the rod nut A onto the push rod with the chamfered side B up Pour in the type and amount of fork oil specified and adjust the oil level see Oil Level Adjustment in this chapter Screw the fork piston rod puller onto the end of the rod Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 Pull up the push rod slowly so as not to spill the fork oil out of the fork tube Install the fork spring into the inner tube and then put the spring seat in place gt Pull the fork spring down while pulling up on the fork piston rod puller A and slip the fork spring holder B in on top the spring seat and under the push rod nut Special Tool Fork Spring Holder 57001 1286 Remove the fork piston rod puller Check the O ring on the top plug and replace it with a new one if damaged Holding the top plug A with a wrench tighten the push rod nut B against the top plug Torque Push Rod Nut 15 N m 1 5 kg m 11 ft lb Pull out the fork spring holder raise the outer tube and screw the top plug into it Install the front fork tube into the fork clamps and first tighten the lower clamp bolts Then torque the top plug Torque Front Fork Top Plug 29 N m 3 0 kg m 22 ft lb Front Fork Lower Clamp Bolts 20 N m 2 0 kg m 14 5 ft lb Tighten the upper clamp bolts Torque Front Fork Upper Clamp Bolt 20 N m 2 0 kg
205. round Special Tool Jack 57001 1238 Push and pull on the swingarm A up and down to check for wear A small amount of play on the swingarm is normal and no corrective action is needed However if excessive play is felt remove the uni trak parts from the frame and check for wear Rocker Arm Sleeve Wear Pull out the sleeves A of the rocker arm and measure the outside diameter of the sleeve l f the sleeve is worn past the service limit replace the sleeve Sleeve Outside Diameter Long Standard 21 987 22 000 mm Service Limit 21 85 mm Short Standard 19 000 19 120 mm Service Limit 18 88 mm Rocker Arm Mounting Bott Bend A bent bolt causes vibration poor handling and instability T o measure bolt runout remove the bolt place it in V blocks and set a dial gauge to the bolt at a point halfway between the blocks Turn A the bolt to measure the runout The amount of dial variation is the amount of runout l f runout exceeds the service limit replace the bolt Bolt Runout Standard Service Limit Under 0 1 mm 0 2 mm http mototh com STEERING 13 1 Steering Table of Contents Exploded View 13 2 Specifications 13 3 Steering 13 4 Inspection 13 4 Adjustment 13 4 Stem Stem Bearing Removal 13 5 Stem Stem Bearing Installation 13 6 Steering Maintenance 13 8 Stem Bearing Lubrication 13 8 Stem Warp 13 8 http mototh com 13 2 STEERING Exploded View KLX2
206. s reservoir cap and the end of the gas reservoir are not aligned the circlip is not correctly fitted in the groove in the gas reservoir or is deformed In this case the oil and internal parts could explode out of the reservoir when injecting the nitrogen gas or while riding the motorcycle Pour SAE 5W or Bel Ray SE2 40 oil into the rear shock body to 45 mm A from the upper end of the rear shock body Insert the piston A end of the push rod assembly into the rear shock body slowly and pump the push rod until all the air is forced out of the rear shock body Push the seal assembly B into the rear shock body until it just clears the circlip groove http mototh com 12 24 SUSPENSION Check the circlip l f it is deformed or damaged replace it with a new one Fit the circlip A into the groove in the rear shock body AWARNING If the circlip is not a certain fit in the groove in the rear shock body the push rod assembly may come out of the shock absorber when injecting the nitrogen gas or riding the motorcycle Pull up the push rod assembly B against the circlip Force the stop C into the rear shock body by lightly tapping around the edge of the stop with a mallet Hold the lower end of the push rod assembly in a vise Pump the rear shock up and down several times and then leave it in the fully extended position for about three minutes Remove the air bleeder bolt A from the upp
207. sion control system CA check Spark arrester US clean Engine oil change Oil filter replace Radiator hoses connections check Coolant change Fuel hose replace Clutch adjust Drive chain wear check Drive chain lubricate Drive chain slack check Brake pad wear check Brake fluid level check Brake fluid change Brake hose and pipe replace Brake master cylinder cup and dust seal replace Caliper piston seal and dust seal replace Brake light switch check Steering play check http mototh com GENERAL INFORMATION 1 13 t For higher odometer readings repeat at the frequency interval established here Replace add adjust clean or torque if necessary CA California Model US U S Model Steering stem bearing lubricate Front fork oil change Tire wear check Spoke tightness and rim runout check Swingarm pivot uni trak linkage lubricate General lubrication perform Nut bolt and fastener tightness check http mototh com 1 14 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasekt Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads LG Apply liquid gasket to the threads SS Apply silicone sealant to the th
208. spark plug B Unscrew the mounting bolt and remove the ignition coil C Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the 3 needle method Special Tool Coil Tester 57001 1242 N O T E O Since a tester other than the coil tester special tool may produce a different arcing distance the coil tester special tool is recommended for reliable results Remove the ignition coil Connect the ignition coil with the spark plug cap left installed on the sparkplug lead A to the tester B and measure the arcing distance AWARNING To avoid extremely high voltage shocks do not touch the coil or lead l f the distance reading is less than the specified value the ignition coil or spark plug cap is defective Ignition Coil Arcing Distance Standard 7 mm or more T o determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil lead l f the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap Measuring coil resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and shorts resultin
209. st you in locating a desired topic or procedure Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the specific topic required General Information Fuel System Cooling System Engine Top End Engine Right Side Left Side Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix Supplement 1994 Models http mototh com GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing 1 1 Model Identification 1 4 General Specifications 1 6 Periodic Maintenance Chart KLX250D 1 10 Periodic Maintenance Chart KLX250E 1 12 Torque and Locking Agent 1 14 Special Tools and Sealant 1 17 Cable Wire and Hose Routing 1 23 http mototh com 1 2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Dirt Before re
210. stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine No spark spark weak Ignition switch not on KLX250E Engine stop switch turned off Clutch lever not pulled in or gear not in neutral KLX250E Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect CDI unit trouble Pickup coil trouble Ignition coil trouble Ignition coil resistor open Flywheel magneto damaged Ignition or engine stop switch shorted Neutral switch trouble KLX250E Interlock diode unit trouble KLX250E Wiring shorted or open Fuel air mixture incorrect Pilot screw and or idle adjusting screw maladjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or missing Starter jet clogged Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trouble
211. t All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products Group Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts Kawasaki Heavy Industries Ltd 1997 First Edition 1 Aug 27 1997 M http mototh com LIST OF ABBREVIATIONS A ampere s lb pounds s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per s
212. t http mototh com 3 6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motorcycle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart see the General Information chapter AWARNING To avoid burns do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot Wait until it cools down Coolant Inspection Coolant Deterioration Visually inspect the coolant in the reservoir tank A Reservoir Tank C LOW Mark B FULL Mark D Cap NOTE OBe sure to inspect the coolant at the reservoir tank If the coolant is checked at the radiator by removing the radiator cap the air must be bled into the cooling system l f whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system O If the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Situate the motorcycle so that it is perpendicular to the ground Check the coolant level through the level marks on the reservoir tank The coolant level should be between the FULL and LOW marks NOTE O Check the level when the engine is cold room or ambient temper ature ODo not check the level through t
213. t Reservoir Cap Screws Brake Lever Pivot Locknut Front Master Cylinder Clamp Bolts Caliper Bleed Valves Front Rear Front Brake Disc Mounting Bolts Rear Brake Disc Mounting Bolts Caliper Mounting Bolts Front Rear Rear Brake Push Rod Locknut Brake Pad Bolts Front Rear 25 1 5 5 9 8 8 7 8 9 8 23 25 17 18 2 5 0 15 0 6 0 9 0 8 1 0 2 3 2 5 1 75 1 8 18 0 13 in lb 52 in lb 78 in lb 69 in lb 87 in lb 16 5 18 0 12 7 13 Suspension Conventional Type Front Top Plug Front Fork Upper Clamp Bolts Front Fork Lower Clamp Bolts Front Fork Oil Drain Screw Front Fork Cylinder Valve ASSY Upside Down Type Front Top Plug Front Fork Upper Clamp Bolts Front Fork Lower Clamp Bolts Front Fork Oil Drain Screw Push Rod Nut Front Fork Cylinder Valve ASSY Rear Shock Absorber Upper Mounting Bolt Rear Shock Absorber Lower Mounting Nut 29 20 20 1 5 71 29 20 23 15 54 39 39 3 0 2 0 2 0 0 15 7 2 3 0 2 0 2 3 1 5 5 5 4 0 4 0 22 14 5 14 5 13 in lb 52 22 14 5 16 5 11 40 29 29 LG L L http mototh com 1 16 GENERAL INFORMATION FFFaaasssttteeennneeerrr Torque RRReeem m maaarrrkkksss N m kg m ft lb Swing Arm Pivot Shaft Nut Rocker Arm Pivot Nut Tie Rod Mounting Nuts Upper Lower 88 98 81 9 0 10 0 8 3 65 72 60 Steering Handlebar Clamp Bolts Steering Stem Head Nut Front Fork Upper Clamp Bolts Front Fork Lower Clamp Bolts Steering Stem Locknut
214. t cover A on the push rod B out of place and remove the circlip C Special Tool Inside Circlip Pliers 57001 143 Pull out the push rod with the piston stop D Take out the piston E secondary cup F primary cup G and return spring H CAUTION Do not remove the secondary cup from the piston since removal will damage it Remove the circlip I take off the connector J and O ring K http mototh com Assembly Notes Before assembly clean all parts including the master cylinder with brake fluid or alcohol Apply brake fluid to the removed parts and to the inner wall of the cylinder CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventuality deteriorate the rubber used in the disc brake Take care not to scratch the piston or the inner wall of the cylinder Tighten the brake lever pivot bolt and the locknut securely Torque Brake Lever Pivot Locknut 5 9 N m 0 6 kg m 52 in lb Inspection Visual Inspection Disassemble the front and rear master cylinders Check that there are no scratches rust or pitting on the inner wall of each master cylinder A and on th
215. t lb Front Fork Axle Nut 88 N m 9 0 kg m 65 ft lb Front Fork Caliper Mounting Bolts 25 N m 2 5 kg m 18 ft lb Check the front brake operation after installation Disassembly Oil Change Remove the front fork and drain the fork oil see Oil Level Adjustment Remove the push rod nut A and take out the collar B and spring guide C Clean the bottom of the inner tube Remove the cap on the bottom of the inner tube Hold the front fork in a vise Slip the fork cylinder holder B down over the push rod to engage the top of the cylinder unit A Special Tool Fork Cylinder Holder 57001 1287 While holding the fork cylinder unit from turning with the special tool remove the cylinder valve assembly C from the bottom of the inner tube with an Allen wrench SUSPENSION 12 13 http mototh com 12 14 SUSPENSION A Inner Tube B Cylinder Valve Assembly C O ring D Gasket Pull the push rod A and cylinder unit assembly B out the top of the outer tube C Separate the inner tube from the outer tube as follows O Slide up the dust seal O Remove the retaining ring A from the outer tube O Grasp the outer tube and stroke the inner tube up and down several times The shock to the fork seal separates the inner tube from the outer tube Remove the guide bushings A washer B oil seal C retaining ring and dust seal from the inner tube http mototh com
216. t the 2 pin connector A in the fan leads Using two auxiliary wires supply battery power B to the fan motor l f the fan does not rotate at this time the fan motor is defective and must be replaced Fan Relay Inspection Remove the seat Remove the fan relay A connected http mototh com 15 26 ELECTRICAL SYSTEM Connect the hand tester A and 12 V battery B to the fan relay C as shown If the relay does not work as specified the relay is defective Replace the relay Testing Relay Tester Range x l Q Criteria When battery is connected gt 0Q When battery is disconnected gt Q Relay Coil Terminal 1 and 2 Relay Switch Terminals 3 and 4 Radiator Fan Circuit 1 Radiator Fan Motor 2 Fan Switch 3 Radiator 4 Fan Relay 5 Magneto 6 Regulator Rectifier http mototh com ELECTRICAL SYSTEM 15 27 Coolant Temperature Warning System KLX250E When the ignition switch is turned on with the transmission in neutral the warning light flashes regardless of coolant temperature This is to show if the light bulb has burned out If the water temperature is high the warning light flashes even if the transmission is in gears until water temperature falls If the system does not function properly inspect it as follows Warning System Inspection 1 The warning light A does not flash when the ignition switch is turned on with the transmission in neutral Check the warning
217. tapered roller bearing A http mototh com 13 6 STEERING Drive out the bearing outer races from the head pipe O Remove the outer races passed into the head pipe using the head pipe outer race remover A and hammer the head pipe outer race remover to drive it out Special Tool Head Pipe Outer Race Remover 57001 1107 NOTE Olf either steering stem bearing is damaged it is recommended that both the upper and lower bearing including outer races should be replaced with new ones gt Remove the lower stem bearing A inner race with its grease seal from the stem using suitable tools Stem Stem Bearing Installation Replace the bearing outer races with new ones Apply grease to the outer races and drive them into the head pipe at the same time Special Tool Head Pipe Outer Race Press Shaft 57001 1075 A Head Pipe Outer Race Driver 57001 1076 B Head Pipe Outer Race Driver 57001 1106 C Replace the stem bearing inner races with new ones Apply grease to the lower inner race and drive it onto the stem Special Tool Steering Stem Bearing Driver 57001 137 A Steering Stem Bearing Driver Adapter 57001 1074 B Apply grease to the upper inner race and install it in the head pipe Install the stem through the head pipe and upper bearing install the stem cap and hand tighten the locknut while pushing up on the stem base Install the stem head and washer and tighten the stem he
218. ted of being a problem O Connect the hand tester between the ends of the leads OSet the tester to the x 1 D range and read the tester l f the tester does not read 0 D the lead is defective Replace the lead or the wiring harness B if necessary http mototh com Color Code B K Black B L Blue B R Brown CH C h o c o l a t e DG Dark Green G Green G Y Gray L B Light Blue L G Light Green 0 Orange P Pink P U P u r p l e R Red W White Y Ye I low http mototh com KLX250E Wiring Diagram European model http mototh com ELECTRICAL SYSTEM 15 9 http mototh com ELECTRICAL SYSTEM 15 11 Flywheel Magneto Stator Removal Remove the magneto cover Remove the holding plate A KLX250E Unfit the grommet B holding the stator coil and pick up coil leads out of the notch of cover Unscrew the mounting bolts C and take off the stator D Stator Installation Notes Fit the grommet holding the stator coil and pickup coil leads into the notch of cover securely Route the magneto leads in accordance with the Cable Wire and Hose Routing in the General Information chapter Torque Stator Coil Mounting Bolts 5 9 N m 0 6 kg m 52 in lb Inspection There are three type of magneto problems short open wire burned out or loss in flywheel magnetism A short or open in one of the coil wires will result in either a low output or no output at a
219. ted or open Ignition coil trouble Flywheel magneto damaged Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Air bleed pipe bleed holes clogged Air cleaner clogged poorly sealed or missing Air cleaner duct loose Starter plunger stuck open Fuel to carburetor insufficient Water or foreign matter in fuel Carburetor holder loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect CDI unit trouble Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide smoothly Brakes dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Balancer mechanism malfunctioning Drive train trouble Crankshaft bearing worn or damaged Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark
220. ter Idle Gear Installation Notes Apply molybdenum disulfide grease to the inside of the idle gear A There are circlips B on both sides of the idle gear replace them with new ones Install the idle gear with the flat side toward the crankcase http mototh com 5 14 ENGINE RIGHT SIDE LEFT SIDE External Shift Mechanism Removal Remove Engine Sprocket Cover Engine Sprocket Shift Pedal Guard Shift Mechanism Cover Pull out the external shift mechanism A Remove the nut B and takeoff the gear set lever C Installation Notes Fit the washer A on the shift mechanism shaft Fit the shift shaft in the recess in the left crankcase half Install the shift mechanism cover to the left crankcase half O Use the shift shaft oil seal guide A to protect the oil seal of the shift mechanism cover O Before installing the shift shaft apply high temperature grease to the oil seal lips Special Tool Oil Seal Guide 013 57001 264 A Torque External Shift Mechanism Cover Bolts and Nut 9 8 N m 1 0 kg m 87 in lb External Shift Mechanism Cover Screw 5 4 N m 0 55 kg m 48 in lb Inspection Check the shift shaft A for bending or damage to the splines l f the shaft is bent straighten or replace it If the splines are damaged replace the external shift mechanism Check the return spring B and arm spring C for cracks or distortion l f the springs are damaged in any way repl
221. th the Cable Wire and Hose Routing section in the General Information chapter Install lower ends of the throttle cable in the cable bracket on the carburetor after installing the upper ends of the throttle cable in the grip After the installation adjust each cable properly Operation with incorrectly routed or improperly adjusted cables could result in an unsafe condition Cable Lubrication Whenever the cable is removed and in accordance with the Periodic Maintenance Chart see General Information chapter do the following Apply a thin coating of grease to the cable upper ends A Apply grease http mototh com Lubricate the cable A with a penetrating rust inhibitor Special Tool Pressure Cable Luber k56019 021 Cable Inspection With the throttle cable A disconnected at both ends the cable should move freely within the cable housing l f cable movement is not free after lubricating if the cable is frayed or if the housing is kinked replace the cable FUEL SYSTEM 2 5 http mototh com 2 6 FUEL SYSTEM Carburetor Idle Speed Inspection Start the engine and warm it up thoroughly With the engine idling turn the handlebar to both sides l f handlebar movement changes the idle speed the throttle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Routing in the General Inf
222. the manufacturer of the cleaning product Warm up the engine and run it at normal operating temperature for about ten minutes Stop the engine and drain the cooling system Fill the system with fresh water Warm up the engine and drain the system Repeat the previous two steps once more Fill the system with a permanent type coolant and bleed the air from the system see Air Bleeding http mototh com COOLING SYSTEM 3 11 Water Pump Water Pump Cover Removal Drain the coolant see Coolant Draining Remove the cover bolts A and turn up the water pump cover B with the radiator hose attached Water Pump Cover Installation Notes Installation is the reverse of removal Replace the pump cover gasket with a new one Fill the cooling system see Coolant Filling Bleed the air from the cooling system Impeller Removal Drain the coolant see Coolant Draining Remove the cover bolts and turn up the water pump cover with the radiator hose attached Remove the impeller nut B and pull out the impeller A and the O ring Impeller Installation Before installing the impeller A fit the O ring B in the impeller nut Install the impeller onto the water pump shaft and tighten the impeller nut Torque Impeller Nut 7 8 N m 0 8 kg m 69 in lb Impeller Assembly Notes Clean the sliding surface of the mechanical seal with a high flash point solvent and
223. the movement of inlet valves valves to rear When the valves have just finished opening and closing moving downwards and returning upwards turn the crankshaft in the same direction about another 1 2 turn until the T mark B on the magneto flywheel is aligned with the notch A on the upper hole of the magneto cover C OAt this point the marks on the camshaft sprockets point forward and line up with the surface of the cylinder head NOTE O Check the valve clearance using this method only Checking the clearance at any other cam position may result in improper valve clearance Using a thickness gauge A measure the clearance between the cam lob and valve lifter for all four valves l f the valve clearance is incorrect adjust it Valve Clearance when cold Inlet 0 10 0 19 mm Exhaust 0 15 0 24 mm Clearance Adjustment Remove the camshaft A see Camshaft Removal Remove the valve lifter B Remove the shim C Referring to the Valve Clearance Adjustment Chart select a new shim W h e n installing the shim face the marked side A toward the valve lifter B At this time apply high temperature grease to the shim or the valve lifter B to keep the shim in place during camshaft installa tion Install the camshafts Be sure to time the camshafts properly Remeasure the valve clearance that was adjusted Readjust if necessary http mototh com 4 16 ENGINE TOP END Rem
224. the same time that a gear is repaired or replaced the driving gear should also be inspected and repaired or replaced if necessary http mototh com 8 14 CRANKSHAFT TRANSMISSION Gear Dog I Gear Dog Hole Damage Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes Ball Bearing Wear Check the ball and needle bearings in the crankcase O Since the ball and needle bearing are made to extremely close tolerances the wear must be judged by feel rather than measurement Clean each bearing in a high flash point solvent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin the bearing by hand to check its condition l f the bearing is noisy does not spin smoothly or has any rough spots replace it http mototh com WHEELS TIRES 9 1 Wheels Tires Table of Contents Exploded View 9 2 Specifications 9 3 Wheels Rims 9 4 Front Wheel Removal 9 4 Front Wheel Installation Notes 9 4 Rear Wheel Removal 9 5 Rear Wheel Installation Notes 9 5 Inspection 9 6 Spoke Inspection 9 6 Rim Inspection 9 7 Axle Inspection 9 7 Tires 9 8 Air Pressure Inspection Adjustment 9 8 Inspection 9 8 Removal 9 9 Installation Notes 9 9 Hub Bearings 9 10 Removal Notes 9 10 Installation Notes 9 10 Inspection 9 10 Speedometer Gear Housing 9 11 Disassembly and Assembly 9 11 Lubrication 9 11 http mototh c
225. them The last is a friction plate CAUTION If dry steel plates and friction plates are installed apply engine oil to the surfaces of each plate to avoid clutch plate seizure Tighten the clutch spring bolts Torque Clutch Spring Bolts 3 2 N m 0 33 kg m 29 in lb Install the conical spring washer so that the concave surface B faces toward the clutch hub A Use the flywheel holder to prevent the clutch from rotating Special Tool Flywheel Holder 57001 1313 Tighten the clutch hub nut Torque Clutch Hub Nut 78 N m 8 0 kg m 58 ft lb Apply molybdenum disulfide grease to the rubbing portion of the clutch spring plates pusher Friction and Steel Plate Wear Damage Inspection Visually inspect the friction and steel plates to see if they show any signs for seizure or uneven wear l f any plates show signs of damage replace the friction plates and steel plates as a set Measure the thickness of the friction A and steel plates with vernier calipers l f they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 92 3 08 mm Service Limit 2 7 mm http mototh com 5 10 ENGINE RIGHT SIDE LEFT SIDE Friction and Steel Plate Warp Inspection Place each friction plate or steel plate on a surface plate C and measure the gap between the surface plate and each friction plate or steel plate A with a thickness gauge B The gap is
226. turate the sponge filter with 2 stroke racing oil or high quality foam air filter oil squeeze out the excess then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the sponge filter Assemble the element and install it http mototh com 2 14 FUEL SYSTEM Fuel Tank Removal Remove Radiator Covers Seat Turn the fuel tap to the OFF position Pull the fuel hose off the fuel tap Take the breather hose A off the handlebar KLX250D AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine KLX250D or turn the ignition switch OFF KLX250E Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Unscrew the fuel tank mounting bolts B and remove the tank Installation Notes Check the rubber dampers A i f the dampers are damaged or deteriorated replace them Be sure the fuel hose is clamped to the fuel tap to prevent leaks Inspection Visually inspect the gasket A on the tank cap for any damage Replace the gasket if it is damaged CAUTION Do not apply compressed air to the air vent holes B in the tank cap This could cause damage to and clogging of the labyrinth in the cap http mototh com Cleaning AWARNING Clean the tank in a well venrilated area and take care that there are no sparks or fla
227. ual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s systems and assists in locating their chapters Each chapter in turn has its own compre hensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instructions or procedures which if not correctly followed could result in personal injury or loss of life This caution symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information http mototh com NOTE This note symbol indicates points of partic ula
228. uled mainte nance Use proper tools and genuine Kawasaki JET SKI watercraft parts Special tools gauges and testers that are necessary when servicing Kawasaki JET SKI watercraft are introduced by the Special Tool Manual Genuine part provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don t take shortcuts Remember to keep complete records of mainte nance and repair with dates and any new parts installed H o w to Use this Manual In preparing this manual we divided the product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own compre hensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARNING and CAUTION symbols he
229. use the tires until they are bald Remove any imbedded stones or other foreign particles from the tread Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indicate internal damage requiring tire replacement Measure the tread depth at the center of the tread with a depth gauge A OTake measurement at several places since the tire may wear unevenly l f any measurement is less than the service limit replace the tire Tread Depth KLX250D Front KLX250E Front Standard 10 8 mm Standard 8 3 mm Service Limit 2 mm Service Limit 2 mm Rear Rear Standard 16 2 mm Standard 11 8 mm Service Limit 2 mm Service Limit 2 mm AWARNING To ensure safe handling and stability use only the recommended standard tires for replacement inflated to the standard pressure NOTE O Check and balance the wheel when a tire is replaced with a new one Standard Tire KLX250D Front KLX250E Front Size 80 100 21 51M Size 3 00 21 51P Make DUNLOP Make DUNLOP Type Tube D752F AS K490 Type Tube D603 Rear Rear Size 100 100 18 59M Size 4 60 18 63P Make DUNLOP Make DUNLOP Type Tube D752 AS K695 Type Tube D603 Air Pressure Inspection I Adjustment Using an air pressure gauge A measure the tire air pressure when the tires are cold Adjust the tire air pressure according to the following specifications if necessary Air Pressure w
230. ustment too hard Too soft Front fork oil insufficient and or leaking Front fork oil viscosity too low Front fork damper adjustment too soft Upside down type Front fork rear shock absorber spring weak Rear shock absorber oil leaking Rear shock absorber adjustment too soft Tire air pressure too low Brake Doesn t Hold Air in the brake line Pad or disc worn http mototh com 16 8 APPENDIX Nut Bolt and Fastener Tightness Tightness Inspection Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature If there are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications For each fastener first loosen it by 1 2 turn then tighten it l f cotter pins are damaged replace them with new ones Nut bolt and fastener to be checked Wheels Front Axle Front Axle Clamp Nuts Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknuts KLX250E Euro Rear Sprocket Nuts Brakes Front Master Cylinder Clamp Bolts Caliper Bolts Rear Master Cylinder Bolts Brake Pedal Cotter Pin Brake Lever Pivot Nut Brake Rod Joint Cotter Pin Sus
231. ustralia M o d e l http mototh com GENERAL INFORMATION 1 25 Model KLX250E F 1 To Right Handlebar Switch 2 Horn 3 Hang on the hook 4 Grave Earth Lead 5 Band 6 Fasten the Harness and coupler cover 7 Set the white mark of Harness to the Pipe 8 Side Stand Unit 9 Fan Relay 10 Clamp the Terminal Cover and Lead with Fender Clamp LH amp R H 21 Fan Switch 22 Brake Switch 11 Fasten the Lead so as to no slack with Clamp 12 LH Turn Signal Light Lead 13 R H Turn Signal Light Lead 14 Licence Plate Light Lead 15 Tail Light Lead 16 Condenser 17 To Tail Light 18 Run the Lead under the Ignition Coil Don t press the Lead 19 Run the Lead through the notch 20 Fasten with Clamp http mototh com 1 26 GENERAL INFORMATION Section A Section B 1 Fasten the Harness and Clamp with together 2 Run the Lead through under the Meter Cable 3 To the Head Light 4 To the Position Light 5 Fasten the Harness at the white mark with tie lap 92072 1288 with ring and hang the hole of the tie lap onto the bracket hook 1 Fasten the Coupler 92037 1193 Switches LH amp R H 2 Bracket Hook of Handlebar Section C Section D 1 Run the Harness through in the Fan Stay 2 Fasten the Harness and cover with Clamp 3 Run the Harness through the notch of Radiator 4 Fasten the Main Earth Lead and the Earth Lead of Engine Stop Switch together 1 Air Intake Duct 2 Run the Harness through in front of
232. utch lever play excessive Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch release mechanism trouble Clutch hub nut loose Clutch hub spline damaged Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork worn bent Gear groove worn Gear dogs and or dog recesses worn Shift drum groove worn Gear positioning lever spring weak or broken Shift fork pin worn Drive shaft output shaft and or gear spiines worn Overshifts Gear positioning lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise Knocking CDI unit trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearings worn Valve lifter worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring worn broke
233. ve the top and second rings with piston ring pliers A If the special tool is not available carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring to remove it t Remove the 3 piece oil ring with your thumbs in the same manner Special Tool Piston Ring Pliers 57001 115 http mototh com 4 26 ENGINE TOP END Piston Installation Notes The arrow A on the top of the piston must point toward the front When installing a piston pin snap ring B compress it only enough to install it and no more CAUTION Do not reuse snap ring as removal weakens and deforms them They could fall out and score the cylinder wall Fit a new piston pin snap ring into the side of the piston so that the ring opening does not coincide with the notch C in the edge of the piston pin hole Oil Ring Installation O First install the expander A in the piston oil ring groove so that the expander ends B butt together never overlap O Install the upper and lower steel rails There is no UP or DOWN to the rails They can be installed either way Do not mix up the top and second ring Install the top ring A and second ring B so that the R or 2R marks face up Position each piston ring so that the openings in the top ring A and oil ring steel rails C face forwards and the second ring B and oil ring expander D openings face rearwards The openings of the oil ring st
234. y the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Fork Spring Free Length Standard 506 mm Service Limit 496 mm Upside down Type Air Pressure Adjustment The standard air pressure in the fork legs is atmospheric pressure The air pressure in the fork legs increases as the fork heats up so the fork action will get stiffer as the vehicle operation progresses Park the vehicle on level ground Remove the screws A at the top of the front fork top plugs http mototh com SUSPENSION 12 11 Compression Damping Adjustment Clean the bottom of the fork tubes Remove the caps on the bottom of the fork tubes To adjust compression damping turn the adjuster A on the front fork cylinder valve with the blade of a screwdriver until you feel a click Adjust the compression damping to suit your preference under special conditions CAUTION The left and right fork legs must have the same shock damping Seated position with the adjuster turned fully clockwise A Put the caps into the bottom of the fork tubes Compression Damping Adjustment Setting Standard 12nd clicks A Seated positions adjuster turned fully clockwise Oil Level Adjustment Remove the front fork see Front Fork Removal in this chapter Hold the inner tube lower end in a vise Unscrew the top plug out of the outer tube Push the outer tube all the way down away

Kawasaki KLX 250 old service manual

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