2012 Kawasaki KX250F Owners Manual

2012 Kawasaki KX250F Manual

Get 2012 Kawasaki KX250F PDF manuals and user guides View all 2012 Kawasaki KX250F manuals

2012 Kawasaki KX250F manual content summary:

  • 2012 Kawasaki KX250F | Owners Manual - Page 1
  • 2012 Kawasaki KX250F | Owners Manual - Page 2
  • 2012 Kawasaki KX250F | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING GUIDE TUNING STORAGE j j j j j A Table of Contents is included after the Foreword.
  • 2012 Kawasaki KX250F | Owners Manual - Page 4
    limited to participation in sanctioned competition events upon a closed • The course. vehicle should not be used for general off-road recreational riding. • This Read owner's manual. •
  • 2012 Kawasaki KX250F | Owners Manual - Page 5
    shown below, heed their instructions! Always follow safe FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. DANGER DANGER indicates a hazardous situation which, if not all responsibilities concerning quality, performance, cost of service and/or necessary repairs. NOTICE NOTICE is
  • 2012 Kawasaki KX250F | Owners Manual - Page 6
    conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR
  • 2012 Kawasaki KX250F | Owners Manual - Page 7
    tuned competition machine for participation in racing events. As with any mechanical device, proper care and maintenance are important for trouble-free operation and top performance. This manual is written to enable you to keep your KX properly tuned and adjusted. Due to improvements in design and
  • 2012 Kawasaki KX250F | Owners Manual - Page 8
    (UNI-TRAK®)...Wheels ...Hoses Inspection...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...DFI Self-Diagnosis ...TROUBLESHOOTING GUIDE...TUNING ...Suspension...Gearing...Special Care According to Track Conditions . OPTIONAL PARTS ...PRE-RACE CHECKS AND AFTER-RACE
  • 2012 Kawasaki KX250F | Owners Manual - Page 9
    SPECIFICATIONS 7 SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Road Clearance Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio Fuel System Starting System Ignition System Ignition Timing Lubrication System Spark Plug Spark Plug
  • 2012 Kawasaki KX250F | Owners Manual - Page 10
    8 SPECIFICATIONS TRANSMISSION Transmission Type Clutch Type Driving System Gear Ratio: 1st 2nd 3rd 4th 5th Primary Reduction Ratio Final Reduction Ratio Overall Drive Ratio Engine Oil: Type Viscosity Capacity FRAME Type Steering Angle Caster Trail Tubular, semi-double cradle 42° to either side 28.2°
  • 2012 Kawasaki KX250F | Owners Manual - Page 11
    SPECIFICATIONS 9 Tire Size/Type: Front Rear Rim Size: Front Rear Suspension: Front Rear Front Suspension Travel Rear Wheel Travel Front Fork Oil: Type Capacity (Left Front Fork): Cylinder Unit Outer Tube Capacity (Right Front Fork) BRAKES Type: Front Rear Single disc Single disc 260 mL (8.79 US oz.)
  • 2012 Kawasaki KX250F | Owners Manual - Page 12
    10 GENERAL INFORMATION j GENERAL INFORMATION Location of Parts 1. Clutch Lever 2. Engine Stop Button 3. Fuel Tank Cap 4. Front Brake Fluid Reservoir 5. Front Brake Lever 6. Throttle Grip
  • 2012 Kawasaki KX250F | Owners Manual - Page 13
    GENERAL INFORMATION 11 j 1. Front Fork 2. Radiator 3. Fuel Tank 4. Throttle Body Assy 5. Downstream Injector 6. Upstream Injector 7. Seat 8. Air Cleaner Element 9. Brake Disc 10. Brake Caliper 11. Shift Pedal 12. Rear Shock Absorber 13. Swingarm 14. Drive Chain 15. Chain Guide
  • 2012 Kawasaki KX250F | Owners Manual - Page 14
    12 GENERAL INFORMATION j 1. Muffler 2. Rear Brake Fluid Reservoir 3. Rear Shock Absorber Gas Reservoir 4. Kick Pedal 5. Uni-Trak® Tie-Rod and Rocker Arm 6. Oil Level Gauge 7. Rear Brake Pedal 8. Exhaust Pipe
  • 2012 Kawasaki KX250F | Owners Manual - Page 15
    INFORMATION 13 Side Stand To install the side stand, insert its flat end into the rear axle as shown in the figure. NOTE j żSupport the motorcycle with a suitable stand to perform maintenance or adjustment procedures. A. Side Stand B. Rear Axle WARNING Riding with the side stand can cause
  • 2012 Kawasaki KX250F | Owners Manual - Page 16
    immediately. Fuel Requirement: Fuel Type Use clean, fresh unleaded gasoline with a minimum Antiknock Index of 90. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a measure of its resistance to detonation or "knocking". The Antiknock Index is
  • 2012 Kawasaki KX250F | Owners Manual - Page 17
    unleaded gasoline and methanol (wood alcohol) whenever possible, and never use "gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is methyl tertiary butyl ether (MTBE). You may use gasoline containing up
  • 2012 Kawasaki KX250F | Owners Manual - Page 18
    "gasohol" in the fuel system. Before storage it is recommended that you drain all fuel from the fuel system. See the Storage section in this manual. Kick Pedal This motorcycle is equipped with a primary kick starting system. When the clutch lever is pulled, the motorcycle can be started with the
  • 2012 Kawasaki KX250F | Owners Manual - Page 19
    GENERAL INFORMATION 17 Starting the Engine When engine is cold Pull out the idle adjusting screw/choke knob. j • • Shift the transmission into neutral. WARNING Riding with the side stand can cause a crash resulting in injury. Do not start the engine or attempt to ride the motorcycle when the
  • 2012 Kawasaki KX250F | Owners Manual - Page 20
    18 GENERAL INFORMATION NOTE j żIf the engine fails starting, open the throttle fully and depress the kick pedal slowly about 4 a 5 times to clear too rich fuel mixtures in the engine. Then, kick the engine over, leaving the throttle closed. Shifting Gears This motorcycle is equipped with a 5-
  • 2012 Kawasaki KX250F | Owners Manual - Page 21
    GENERAL INFORMATION 19 j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down
  • 2012 Kawasaki KX250F | Owners Manual - Page 22
    20 GENERAL INFORMATION j Stopping the Engine Shift the transmission into the neutral position. • Close the throttle completely and push the engine • stop button. Break-In A brief break-in procedure must be carried out to obtain the proper operating clearances in the engine and transmission, which
  • 2012 Kawasaki KX250F | Owners Manual - Page 23
    GENERAL INFORMATION 21 operation. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. NOTICE When any following parts have been replaced, the same break-in procedure as the new motorcycle must be carried out for one hour
  • 2012 Kawasaki KX250F | Owners Manual - Page 24
    22 GENERAL INFORMATION j Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and
  • 2012 Kawasaki KX250F | Owners Manual - Page 25
    GENERAL INFORMATION 23 Properly installed Engine Sprocket ...No wear or damage Frame Tires ...Overall condition good No wear or damage Pressure correct Air valve cap installed Spokes ...No looseness Drive Chain ...Overall condition good Chain slack correct Oil if necessary Front and Rear Brakes ...
  • 2012 Kawasaki KX250F | Owners Manual - Page 26
    24 GENERAL INFORMATION j After-Race Checks After racing, first clean the motorcycle, then inspect the entire motorcycle with special attention to the air cleaner, brakes, etc. Carry out the general lubrication and make necessary adjustments.
  • 2012 Kawasaki KX250F | Owners Manual - Page 27
    MAINTENANCE AND ADJUSTMENT 25 MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. 1. Periodic
  • 2012 Kawasaki KX250F | Owners Manual - Page 28
    26 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 races (or race (or 2.5 hours) 7.5 hours) Every 6 races (or 15 hours) Every 12 As See races (or required Page 30 hours) 35 - 35 j OPERATION Coolant level - inspect Breather hose - inspect Water hoses and connections - inspect † • • •
  • 2012 Kawasaki KX250F | Owners Manual - Page 29
    MAINTENANCE AND ADJUSTMENT 27 2. Periodic Inspection (Chassis Related Item) FREQUENCY After each Every 3 races (or race (or 2.5 hours) 7.5 hours) OPERATION Brake - adjust † Brake pad wear - inspect † Brake fluid level - inspect † Spoke tightness and rim runout inspect † Drive chain - inspect and
  • 2012 Kawasaki KX250F | Owners Manual - Page 30
    28 MAINTENANCE AND ADJUSTMENT FREQUENCY After each Every 3 races (or race (or 2.5 hours) 7.5 hours) Every 6 races (or 15 hours) Every 12 As See races (or required Page 30 hours) - - - 145 139 - j OPERATION K K Swingarm and UNI-TRAK linkage pivots - inspect † Swingarm and UNI-TRAK linkage pivots -
  • 2012 Kawasaki KX250F | Owners Manual - Page 31
    2 years Every 2 years Every 2 years Every 4 years • - 78 40 - - - - 102 - - K Brake hoses - replace • Every 5 years • †: Replace, add, adjust, clean or torque if necessary. K: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
  • 2012 Kawasaki KX250F | Owners Manual - Page 32
    seizure, accident, and injury. Check the oil level before each ride and change the oil according to the periodic maintenance chart in the Owner's Manual. Because of the semi-dry sump lubrication system, the engine oil level indicated on the oil level gauge will fluctuate depending on the motorcycle
  • 2012 Kawasaki KX250F | Owners Manual - Page 33
    MAINTENANCE AND ADJUSTMENT 31 NOTE żIf no oil appears in the oil level gauge, tip the motorcycle slightly to the right until oil is visible then return to an upright position. If no oil appears even when tipped at an extreme angle, remove the drain bolt to empty any oil that may be in the
  • 2012 Kawasaki KX250F | Owners Manual - Page 34
    32 MAINTENANCE AND ADJUSTMENT the oil filter is replaced, remove the oil filter • When cover bolts and take off the cover with O-ring and spring. the oil filter element with a new one. • Replace Apply grease to the grommet. • Install the oil filter • ward the engine. element with the grommet to- j
  • 2012 Kawasaki KX250F | Owners Manual - Page 35
    . *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. Engine Oil Capacity Capacity: 0.75 L (0.79 US qt) (When filter is
  • 2012 Kawasaki KX250F | Owners Manual - Page 36
    34 MAINTENANCE AND ADJUSTMENT NOTE j żIf unavailable, use equivalent engine oil in accordance with the following table. Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-30, 10W-40, 10W-50 The oil viscosity may need to be changed to accommodate atmospheric conditions in
  • 2012 Kawasaki KX250F | Owners Manual - Page 37
    MAINTENANCE AND ADJUSTMENT 35 Cooling System Water Hoses Check the water hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. WARNING The cooling system can get extremely hot during normal operation and cause serious burns. Do not
  • 2012 Kawasaki KX250F | Owners Manual - Page 38
    36 MAINTENANCE AND ADJUSTMENT the motorcycle perpendicular to the • Situate ground until the radiator cap is level to the ground, so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator. Remove the radiator cap in two steps. First, turn the cap
  • 2012 Kawasaki KX250F | Owners Manual - Page 39
    MAINTENANCE AND ADJUSTMENT 37 the radiator cap and right radiator shroud. • Install Tighten the bolts. • Tightening Torque Radiator Shroud Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) j Coolant Change The coolant should be changed to ensure long engine life, if necessary. Wait for the engine to cool
  • 2012 Kawasaki KX250F | Owners Manual - Page 40
    cooling system are corroded and the NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacture. Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in
  • 2012 Kawasaki KX250F | Owners Manual - Page 41
    MAINTENANCE AND ADJUSTMENT 39 Spark Plug The spark plug should be taken out periodically for inspection and regapping. Measure the gap with a wire-type thickness gauge. If incorrect, adjust the gap to the specified value by bending the outer electrode. Spark Plug Gap CPR8EB-9 CPR9EB-9 If the plug
  • 2012 Kawasaki KX250F | Owners Manual - Page 42
    40 MAINTENANCE AND ADJUSTMENT Spark Plug Removal and Installation j • • Remove the seat (see Air Cleaner section). Remove the bolts and take off the radiator shroud on both sides. • Remove the fuel tank mounting bolt and band. A. Fuel Tank Mounting Bolt B. Band A. Bolts B. Radiator Shroud
  • 2012 Kawasaki KX250F | Owners Manual - Page 43
    MAINTENANCE AND ADJUSTMENT 41 sure to place a piece of cloth around the fuel • Be hose joint. a thin blade screwdriver into the slit on the • Insert joint lock. the driver to disconnect the joint lock. • Turn Pull the fuel hose joint out of the outlet pipe. • j A. Cloth B. Thin Blade Screwdriver
  • 2012 Kawasaki KX250F | Owners Manual - Page 44
    42 MAINTENANCE AND ADJUSTMENT the fuel pump lead connector. • Disconnect Remove the fuel tank. • the cylinder head cover around the spark • Clean plug cap hole before removing the spark plug. the spark plug cap off the plug before remov• Pull ing the spark plug. j A. Fuel Pump Lead Connector
  • 2012 Kawasaki KX250F | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 the spark plug cap as shown in the figure. • Install Pull up the plug cap lightly to make sure of the • installation of the spark plug cap. not fixed completely, reattach them with an adhesive. If the dampers are damaged, replace them with new ones. j A. Spark Plug
  • 2012 Kawasaki KX250F | Owners Manual - Page 46
    44 MAINTENANCE AND ADJUSTMENT the fuel hose joint straight onto the fuel out• Insert let pipe until the hose joint clicks. • Push the joint lock until the hose joint clicks. and pull the fuel hose joint back and forth • Push more than two times, and make sure it is locked and does not come off. j
  • 2012 Kawasaki KX250F | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 NOTE żTo prevent the bottom of the fuel tank from pushing the throttle cables, run the throttle cables over the black connector correctly. installing the fuel tank, make sure that both • After throttle cables (outer) move slightly by pulling them back and forth in
  • 2012 Kawasaki KX250F | Owners Manual - Page 48
    46 MAINTENANCE AND ADJUSTMENT Air Cleaner A clogged air cleaner restricts the air intake, increases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air intake system, which includes the air filter and air duct to the throttle body assy, and the duct clamps and
  • 2012 Kawasaki KX250F | Owners Manual - Page 49
    MAINTENANCE AND ADJUSTMENT 47 the both side covers slightly outward and • Open slide the seat rearward. the wing bolt, and take out the air cleaner • Remove element. j A. Side Covers B. Seat A. Air Cleaner Element B. Wing Bolt inside of the intake tract and throttle body • Check assy for dirt.
  • 2012 Kawasaki KX250F | Owners Manual - Page 50
    48 MAINTENANCE AND ADJUSTMENT the element. If it is dirty, clean it. Also • Inspect check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into the throttle body assy. j WARNING A clogged air cleaner may allow dirt and
  • 2012 Kawasaki KX250F | Owners Manual - Page 51
    MAINTENANCE AND ADJUSTMENT 49 WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point
  • 2012 Kawasaki KX250F | Owners Manual - Page 52
    50 MAINTENANCE AND ADJUSTMENT the air cleaner element so that its tab faces • Install upward and its projections align with the holes in the housing. j A. Apply grease. A. Tab B. Projections C. Holes • Tighten the wing bolt.
  • 2012 Kawasaki KX250F | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 the hooks of the seat under the flange collar • Insert and brackets. the tabs of the side covers into the inside of • Install the seat, and tighten the bolts. j A. B. C. D. Hooks Seat Flange Collar Brackets A. Tabs B. Seat up the rear end of the seat to make sure
  • 2012 Kawasaki KX250F | Owners Manual - Page 54
    52 MAINTENANCE AND ADJUSTMENT Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. Check that the throttle grip has 2 a 3 mm (0.08 a 0.12 in.) of play
  • 2012 Kawasaki KX250F | Owners Manual - Page 55
    MAINTENANCE AND ADJUSTMENT 53 WARNING Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition. Be sure the control cables are adjusted and routed correctly, and are free from damage. Throttle Body Assy Idle Speed Adjustment warm up the
  • 2012 Kawasaki KX250F | Owners Manual - Page 56
    54 MAINTENANCE AND ADJUSTMENT the idle speed. If so, the throttle cable may be improperly adjusted, incorrectly routed, or damaged. Be sure to correct any of these conditions before riding. Cleaning the Throttle Body Assy j WARNING Operation with damaged cables could result in an unsafe riding
  • 2012 Kawasaki KX250F | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 the muffler clamp bolt. • Loosen Remove the muffler mounting bolts, and pull out • the muffler body rearward. • Loosen the air cleaner duct clamp screw. j A. Air Cleaner Duct Clamp Screw A. Muffler Clamp Bolt B. Muffler Mounting Bolts C. Muffler Body
  • 2012 Kawasaki KX250F | Owners Manual - Page 58
    56 MAINTENANCE AND ADJUSTMENT the intake air temperature sensor con• Disconnect nector and upstream injector connector. sure to place a piece of cloth around the fuel • Be hose joint. the both tabs of the joint lock outward and • Open slide the joint lock downward. the fuel hose joint out of the
  • 2012 Kawasaki KX250F | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 the rear frame mounting bolts on the left • Remove and right sides. the rear frame rearward with the air cleaner • Pull housing. sure to place a piece of cloth around the fuel • Be hose joint. a thin blade screwdriver into the slit on the • Insert joint lock. j A.
  • 2012 Kawasaki KX250F | Owners Manual - Page 60
    58 MAINTENANCE AND ADJUSTMENT the driver to disconnect the joint lock. • Turn Pull the fuel hose joint out of the delivery pipe. • • Disconnect the throttle sensor connector. j A. Throttle Sensor Connector A. Turn B. Joint Lock C. Fuel Hose Joint
  • 2012 Kawasaki KX250F | Owners Manual - Page 61
    MAINTENANCE AND ADJUSTMENT 59 the intake air pressure sensor connec• Disconnect tor. • Disconnect the downstream injector connector. • Free the main harness from the clamps. j A. Main Harness B. Clamps A. Intake Air Pressure Sensor Connector B. Downstream Injector Connector
  • 2012 Kawasaki KX250F | Owners Manual - Page 62
    60 MAINTENANCE AND ADJUSTMENT the throttle body assy holder clamp screw. • Loosen Pull the throttle body assy from the holder. • the bolts and clamps, and take off the • Remove throttle pulley cover. j A. Throttle Body Assy Holder Clamp Screw A. Throttle Pulley Cover Bolts B. Throttle Pulley
  • 2012 Kawasaki KX250F | Owners Manual - Page 63
    MAINTENANCE AND ADJUSTMENT 61 the throttle cable bolts, and free the tips of • Loosen throttle cable lower end. the throttle body assy (see Cleaning Your • Clean Motorcycle section). NOTICE If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. the lower
  • 2012 Kawasaki KX250F | Owners Manual - Page 64
    62 MAINTENANCE AND ADJUSTMENT the throttle body assy to the throttle body • Install assy holder. Align the projection with the groove. • Check the throttle body assy is installed securely. • Hold the main harness to the clamps. j A. Main Harness B. Clamps A. Groove B. Projection
  • 2012 Kawasaki KX250F | Owners Manual - Page 65
    MAINTENANCE AND ADJUSTMENT 63 the fuel hose joint straight onto the delivery • Insert pipe. the yellow paint of the hose in the throttle • Check body assy side. • Push the joint lock until the hose joint clicks. and pull the fuel hose joint back and forth • Push more than two times, and make sure it
  • 2012 Kawasaki KX250F | Owners Manual - Page 66
    64 MAINTENANCE AND ADJUSTMENT the intake air pressure sensor connector, • Connect upstream injector connector, downstream injector the rear frame with the air cleaner housing • Install to the throttle body assy. the duct is installed securely. • Check • Check the clamp position as shown in the
  • 2012 Kawasaki KX250F | Owners Manual - Page 67
    MAINTENANCE AND ADJUSTMENT 65 NOTICE When installing the fuel hose joint, do not apply strong force to the upstream injector pipe. The pipe made from resin could be damaged. and pull the fuel hose joint back and forth • Push more than two times, and make sure it is locked and does not come off.
  • 2012 Kawasaki KX250F | Owners Manual - Page 68
    66 MAINTENANCE AND ADJUSTMENT Clutch Clutch Lever Adjustment Proper clutch lever free play is 8 a 13 mm (0.3 a 0.5 in.). Lever play increases with cable stretch and friction plate wear, requiring periodic adjustment. When the clutch lever free play is out of specification, first try adjusting it at
  • 2012 Kawasaki KX250F | Owners Manual - Page 69
    MAINTENANCE AND ADJUSTMENT 67 WARNING Too much cable play can prevent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replacing the cable, be sure the upper end of the clutch outer cable is fully seated in its fitting, or it could slip
  • 2012 Kawasaki KX250F | Owners Manual - Page 70
    68 MAINTENANCE AND ADJUSTMENT • Remove the clutch cover bolts. j the clutch cover and gasket. • Remove Remove clutch spring bolts, clutch pressure • plate andthe springs. A. Bolts B. Clutch Cover A. Clutch Spring Bolts B. Clutch Pressure Plate
  • 2012 Kawasaki KX250F | Owners Manual - Page 71
    MAINTENANCE AND ADJUSTMENT 69 • Remove the friction and steel plates. Steel Plate Thickness Measurement Standard 1.5 a 1.7 mm (0.059 a 0.067 in.) Service Limit 1.4 mm (0.055 in.) j A. Friction Plate B. Steel Plate Friction and Inspection Steel Plates Wear/Damage inspect the friction and
  • 2012 Kawasaki KX250F | Owners Manual - Page 72
    plates, alternat• Install ing between the two; be sure to start and finish with a friction plate. Friction and Steel Plate Installation j Service Limit 0.3 mm (0.012 in.) A. Friction and Steel Plates NOTICE A. Surface Plate B. Friction or Steel Plate C. Thickness Gauge If dry steel plates
  • 2012 Kawasaki KX250F | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 molybdenum disulfide grease to the steel • Apply ball and the contact area of the push rod holder. • Install the steel ball and the push rod holder. the release shaft lever position by measur• Check ing the position distance between the lever and the cable bracket while
  • 2012 Kawasaki KX250F | Owners Manual - Page 74
    72 MAINTENANCE AND ADJUSTMENT Release Shaft Lever Position and Adjusting Washer Selection Position JudgWashers QuanDistance ment Thickness tity 49.2 a 56.5 mm Standard (1.94 a 2.22 in.) More than 56.5 mm (2.22 in.) Less than 49.2 mm (1.94 in.) Too big Too small 1.5 mm (0.06 in.) 1.0 mm (0.04 in.)
  • 2012 Kawasaki KX250F | Owners Manual - Page 75
    MAINTENANCE AND ADJUSTMENT 73 Valve Clearance Valve and valve seat wear decreases valve clearance, upsetting valve timing. Valve Clearance Inspection the spark plug cap (see Spark Plug sec• Remove tion). the cylinder head cover bolts and cylinder • Remove head cover. j NOTICE If valve clearance
  • 2012 Kawasaki KX250F | Owners Manual - Page 76
    74 MAINTENANCE AND ADJUSTMENT the head cover gasket and spark plug • Remove hole gasket. • Remove the two caps from the magneto cover. j A. Head Cover Gasket B. Spark Plug Hole Gasket A. Timing Inspection Cap B. Flywheel Nut Cap
  • 2012 Kawasaki KX250F | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 the piston to the Top Dead Center (TDC) of • Bring its compression stroke to inspect the valve clearance (the position at the end of the compression stroke) by aligning the top mark with the groove on the magneto cover while turning the crankshaft counterclockwise. this
  • 2012 Kawasaki KX250F | Owners Manual - Page 78
    specified • If range, adjust by an authorized Kawasaki dealer or j NOTE żRecord the measured valves clearance. • • a competent mechanic following the instructions in the Service Manual. Using a high-flash point solvent, clean off any oil or dirt that may be on the silicone sealant coating area
  • 2012 Kawasaki KX250F | Owners Manual - Page 79
    on the cylinder head. • Replace the spark plug hole gasket with a new • one, and install it. sure that the upper chain guide is bottomed • Make to the cylinder head cover. j A. Upper Chain Guide B. Cylinder Head Cover A. Head Cover Gasket B. Spark Plug Hole Gasket NOTICE Unless the upper chain
  • 2012 Kawasaki KX250F | Owners Manual - Page 80
    78 MAINTENANCE AND ADJUSTMENT Tightening Torque Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Exhaust System The exhaust system, in particular the muffler body, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon
  • 2012 Kawasaki KX250F | Owners Manual - Page 81
    MAINTENANCE AND ADJUSTMENT 79 the muffler cover bolts. • Remove Remove the muffler mounting bolt. • • Remove the muffler cover with the plastic mallet. j A. Muffler Cover Bolts B. Muffler Mounting Bolt A. Plastic Mallet B. Muffler Cover
  • 2012 Kawasaki KX250F | Owners Manual - Page 82
    80 MAINTENANCE AND ADJUSTMENT the silencer wool with a new one. • Replace Remove the silicone sealant attaching on the muf• fler cover and muffler body. the shape of the silencer wool and install • Arrange the muffler cover to the muffler body. that the exhaust port of the muffler body • Check cover
  • 2012 Kawasaki KX250F | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 a non-permanent locking agent to the muf• Apply fler cover bolts. the muffler cover bolts and apply the sili• Tighten cone sealant to the joint part of the muffler cover and muffler body. tighten the muffler mounting bolt (rear). • Secondly, Thirdly, tighten the muffler
  • 2012 Kawasaki KX250F | Owners Manual - Page 84
    82 MAINTENANCE AND ADJUSTMENT the tabs of the side cover into the slots of • Insert the air cleaner housing, and tighten the bolts. Drive Chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated before riding. If the chain becomes badly worn or
  • 2012 Kawasaki KX250F | Owners Manual - Page 85
    MAINTENANCE AND ADJUSTMENT 83 the drive chain if its slack is out of specifi• Adjust cation. For the rear wheel to be properly aligned, the notch of the left chain adjuster should align with the same swingarm mark that the notch of the right chain adjuster aligns with. Drive Chain Slack 52 a 58 mm
  • 2012 Kawasaki KX250F | Owners Manual - Page 86
    84 MAINTENANCE AND ADJUSTMENT WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and swingarm pivot. both chain adjuster locknuts.
  • 2012 Kawasaki KX250F | Owners Manual - Page 87
    on a straight part of the chain from the center of the 1st pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since overworn sprockets will cause a new chain to wear faster, inspect both the engine and rear sprockets whenever the
  • 2012 Kawasaki KX250F | Owners Manual - Page 88
    in the direction of chain rotation. j A. Weight B. Tape Measure Drive Chain 20-Link Length 317.5 a 318.2 mm (12.50 a 12.53 Standard in.) Service Limit 323 mm (12.7 in.) A. Master Link Clip B. Direction of Chain Rotation NOTE żThe drive system was designed for use with a DAIDO DID 520DMA4 114
  • 2012 Kawasaki KX250F | Owners Manual - Page 89
    Slipper Wear Inspection or damaged. Visually inspect the drive chain guide and replace it if excessively worn or damaged. inspect the upper and lower of the chain • Visually slipper on the swingarm and replace them if worn j A. Chain Guide A. Upper and Lower of the Chain Slipper B. Swingarm
  • 2012 Kawasaki KX250F | Owners Manual - Page 90
    88 MAINTENANCE AND ADJUSTMENT Sprocket Wear Inspection j • Chain Lubrication Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry. A heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide
  • 2012 Kawasaki KX250F | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 Handlebar To suit various riding positions, the handlebar can be adjusted by turning the handlebar holders around. Remove the handlebar pad. Check the handlebar for bent or crack. Remove the handlebar clamp bolts, the clamps and the handlebar. j • • • A. Handlebar
  • 2012 Kawasaki KX250F | Owners Manual - Page 92
    , and turn the adjuster to either side with a wrench. After adjustment, tighten the locknut securely. • • A. B. C. D. Handlebar Clamps Clamp Bolts Gap Supporting Bar not disassemble the supporting bar on the han• Do dlebar. the front brake for the proper brake effect, • Check or no brake drag
  • 2012 Kawasaki KX250F | Owners Manual - Page 93
    MAINTENANCE AND ADJUSTMENT 91 the braking power and check that there is no • Test brake drag. NOTICE Do not spill brake fluid onto any painted surface. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the brake
  • 2012 Kawasaki KX250F | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT j A. Rear Brake Reservoir B. Lower Level Line A. Front Brake Reservoir B. Upper Level Line the brake fluid in the front or rear brake reservoir • If is below the lower level line, check for fluid leaks in the brake line and fill the reservoir to the upper level line
  • 2012 Kawasaki KX250F | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 WARNING Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled
  • 2012 Kawasaki KX250F | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT Steering The steering should always be kept adjusted so that the handlebar will turn freely but not have excessive play. the figure. If play is felt, the steering is too loose and needs to be adjusted. j Steering Inspection check the steering adjustment, raise the
  • 2012 Kawasaki KX250F | Owners Manual - Page 97
    MAINTENANCE AND ADJUSTMENT 95 Steering Adjustment Raise the front wheel off the ground using a jack (special tool: 57001-1238) and attachment (special tool: 57001-1252 or 1608). Unlock the clamp of the number plate. Remove the bolt. Clear the holes and remove the number plate. the handlebar (
  • 2012 Kawasaki KX250F | Owners Manual - Page 98
    96 MAINTENANCE AND ADJUSTMENT the steering stem locknut with a stem nut • Turn wrench (special tool: 57001-1100) to obtain the proper adjustment. Tightening Torque Steering Stem Head Nut: 98 N·m (10.0 kgf·m, 72 ft·lb) Front Fork Clamp Bolts (Upper): 23 N·m (2.3 kgf·m, 17 ft·lb) j NOTE żTighten
  • 2012 Kawasaki KX250F | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 NOTICE Front Suspension Front Fork Inspection the brake lever, pump the front fork back • Holding and forth manually to check for smooth operation. inspect the front fork for oil leakage, scor• Visually ing or scratches on the outer surface of the inner If
  • 2012 Kawasaki KX250F | Owners Manual - Page 100
    98 MAINTENANCE AND ADJUSTMENT This adjustment affects how quickly the fork compresses. Depending on the model, the fork compression damping adjuster has at least 22 positions. The fully seated position (adjuster turned fully clockwise) is the hardest setting. Turning the adjuster 7 clicks
  • 2012 Kawasaki KX250F | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 j A. Screw B. Front Fork Top Plug C. Front Fork (Left Side) A. Screw B. Front Fork Top Plug C. Front Fork (Right Side) Rebound Damping Adjustment (Left Fork only) the bottom of the left fork tube. • Clean To adjust rebound damping, turn the adjuster • on the
  • 2012 Kawasaki KX250F | Owners Manual - Page 102
    100 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings j A. Rebound Damping Adjuster B. Left Front Fork Cylinder Valve A. Seated Position (Adjuster Turned Fully Clockwise) B. Softer (Counterclockwise) C. Harder (Clockwise) D. Standard Setting *: Number of turns counterclockwise usable
  • 2012 Kawasaki KX250F | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 with a flat-head screwdriver. Adjust the compression damping to suit your preference under certain conditions. Compression Damping Adjuster Settings j NOTICE Do not force the compression damping adjuster beyond the fully seated position, or the adjusting mechanism
  • 2012 Kawasaki KX250F | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT the spring preload to suit your preference under certain conditions. Spring Preload Adjuster Settings j NOTICE Do not force the spring preload adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. A. Seated Position (Adjuster Turned
  • 2012 Kawasaki KX250F | Owners Manual - Page 105
    (special tool: 57001-1645). A. Front Fork Clamp Bolts (Upper) B. Top Plug Wrench (Special Tool: 57001-1645) the motorcycle using a jack (special tool: • Support 57001-1238) and attachment (special tool: 57001 NOTE żDo not take off the base valve assembly (left fork only). -1252 or 1608
  • 2012 Kawasaki KX250F | Owners Manual - Page 106
    104 MAINTENANCE AND ADJUSTMENT NOTICE 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 the disc does not touch the ground. j A. Front Axle Nut B. Left Front Axle Clamp Bolts (Loosen) C. Bolts D. Front Brake Caliper E.
  • 2012 Kawasaki KX250F | Owners Manual - Page 107
    MAINTENANCE AND ADJUSTMENT 105 the front fork clamp bolts (lower). • Loosen Remove the front fork tubes by pulling down while • twisting it. Standard Length 317 a 321 mm (12.48 a 12.64 in.) j A. Front Fork Clamp Bolts (Lower) B. Pull down by twisting. C. Front Fork Tube A. Length B. Axle Holder
  • 2012 Kawasaki KX250F | Owners Manual - Page 108
    106 MAINTENANCE AND ADJUSTMENT Left Front Fork Using the top plug wrench (special tool: 57001 -1645), remove the left front fork cylinder unit from the outer tube and slowly slide down the outer tube. j • a drain pan under the front fork and drain • Place fork oil. NOTE żPump the outer tube
  • 2012 Kawasaki KX250F | Owners Manual - Page 109
    MAINTENANCE AND ADJUSTMENT 107 install the left front fork cylinder unit to • Temporarily the outer tube using the top plug wrench (special tool: 57001-1645). • Loosen the adjuster assembly completely. NOTE żWhen removing the adjuster assembly, do not force to loosen it at once using an impact
  • 2012 Kawasaki KX250F | Owners Manual - Page 110
    108 MAINTENANCE AND ADJUSTMENT • Remove the push rod. j A. Locknut B. Wrench C. Left Front Fork Adjuster Assembly A. Push Rod NOTICE Removing the locknut and pushing the piston rod thread into the left front fork cylinder unit will damage the oil seal. Do not remove the locknut from the piston
  • 2012 Kawasaki KX250F | Owners Manual - Page 111
    MAINTENANCE AND ADJUSTMENT 109 the fork leg from the vise. • Remove Loosen the front fork cylinder unit with the top • plug wrenchleft (special tool: 57001-1645). the left front fork cylinder unit from the • Remove outer tube. j A. Left Front Fork Cylinder Unit B. Left Front Fork Outer Tube C. Top
  • 2012 Kawasaki KX250F | Owners Manual - Page 112
    Unit D. Hexagon Box Wrench żSlowly compress the piston rod until it stops so NOTICE Disassembling the left front fork base valve assembly can lead to trouble. Do not disassemble the left front fork base valve assembly. that the left front fork base valve assembly can be removed easily. the left
  • 2012 Kawasaki KX250F | Owners Manual - Page 113
    MAINTENANCE AND ADJUSTMENT 111 the fork oil from the left front fork cylinder • Drain unit by pumping the piston rod several times. the front fork at the inverted position for more • Hold than 20 minutes to allow the fork oil to fully drain. the threads of the left front fork cylinder unit • Clean
  • 2012 Kawasaki KX250F | Owners Manual - Page 114
    112 MAINTENANCE AND ADJUSTMENT the piston rod fully stretched, pour 260 mL • With (8.79 US oz.) of fork oil. the piston rod slowly several times to expel • Pump air. j A. Fork Oil B. Left Front Fork Cylinder Unit A. Pump B. Piston Rod Recommended Fork Oil SHOWA SS19 or equivalent the piston rod
  • 2012 Kawasaki KX250F | Owners Manual - Page 115
    MAINTENANCE AND ADJUSTMENT 113 j A. 115 a 123 mm (4.53 a 4.84 in.) B. Oil Level A. O-rings B. Bushings the O-rings on the left front fork base • Replace valve assembly with new ones. specified fork oil to the O-rings and bushings • Apply on the left front fork base valve assembly. the piston
  • 2012 Kawasaki KX250F | Owners Manual - Page 116
    by pumping the piston rod to full stroke. j NOTICE Be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil flies out from the oil hole of the left front fork cylinder unit. A. Top Plug Wrench (Special Tool: 57001-1645) B. Left Front
  • 2012 Kawasaki KX250F | Owners Manual - Page 117
    MAINTENANCE AND ADJUSTMENT 115 the extra oil from the left front fork cylinder • Drain unit oil hole. out the extra oil from the oil hole of the left • Blow front fork cylinder unit with the compressed air the piston rod end with a heavy cloth to • Protect prevent damage. the piston rod to full
  • 2012 Kawasaki KX250F | Owners Manual - Page 118
    116 MAINTENANCE AND ADJUSTMENT the oil off completely from the left front fork • Wipe cylinder unit. Compress the piston rod to 200 a 250 mm (7.87 •a 9.84 in.) and hold the left front fork cylinder unit upright position for 10 minutes. oil leaks from the cylinder unit, replace the left • If front
  • 2012 Kawasaki KX250F | Owners Manual - Page 119
    MAINTENANCE AND ADJUSTMENT 117 wipe off the fork oil from the left front • Completely fork cylinder unit. • Insert above-mentioned parts into the fork. tighten the left front fork cylinder unit • Temporarily using the top plug wrench (special tool: 57001 -1645). j A. Left Front Fork Cylinder Unit
  • 2012 Kawasaki KX250F | Owners Manual - Page 120
    118 MAINTENANCE AND ADJUSTMENT the O-ring on the left front fork adjuster • Replace assembly with a new one and apply specified fork the push rod into the piston rod. • Insert Install the left front fork adjuster assembly to the • push rod. oil to the O-ring. turn the left front fork adjuster
  • 2012 Kawasaki KX250F | Owners Manual - Page 121
    MAINTENANCE AND ADJUSTMENT 119 j A. Locknut B. Wrench C. Left Front Fork Adjuster Assembly A. Axle Holder Part B. Left Front Fork Adjuster Assembly • Apply a non-permanent locking agent and tighten the left front fork adjuster assembly to the specified torque. the length at assembly and at
  • 2012 Kawasaki KX250F | Owners Manual - Page 122
    120 MAINTENANCE AND ADJUSTMENT j A. Top Plug Wrench (Special Tool: 57001-1645) B. Left Front Fork Cylinder Unit C. Left Front Fork Outer Tube A. Left Front Fork Outer Tube B. Fork Oil the specified amount of fork oil into the left • Pour front fork outer tube. Recommended Fork Oil SHOWA SS19 or
  • 2012 Kawasaki KX250F | Owners Manual - Page 123
    MAINTENANCE AND ADJUSTMENT 121 Right Front Fork Check the position of the right front fork spring preload adjuster so that it can be installed in the original position. • j A. Left Front Fork Cylinder Unit B. Left Front Fork Outer Tube C. Top Plug Wrench (Special Tool: 57001-1645) A. Right Front
  • 2012 Kawasaki KX250F | Owners Manual - Page 124
    122 MAINTENANCE AND ADJUSTMENT the top plug wrench (special tool: 57001 • Using -1645), remove the top plug from the right front fork outer tube and slowly slide down the outer tube. the clamps (special tool: 57001-1693) as • Install shown in the figure, and tighten the bolts. the holders of the
  • 2012 Kawasaki KX250F | Owners Manual - Page 125
    MAINTENANCE AND ADJUSTMENT 123 the right front fork tube on the base (special • Set tool: 57001-1753) as shown in the figure. the compression shaft and screw the exten• Insert sion rod (special tool: 57001-1753). the other side compression shaft same • Set process. j A. Base (Special Tool: 57001-
  • 2012 Kawasaki KX250F | Owners Manual - Page 126
    124 MAINTENANCE AND ADJUSTMENT the extension rods (special tool: 57001 • Screw -1753) into the base (special tool: 57001-1753). the nuts. • Install Screw • out. in the nuts until the piston rod nut comes j A. Extension Rod (Special Tool: 57001-1753) B. Base (Special Tool: 57001-1753) A. Nuts
  • 2012 Kawasaki KX250F | Owners Manual - Page 127
    MAINTENANCE AND ADJUSTMENT 125 the piston rod nut with a spanner, loosen • Holding the right front fork spring preload adjuster. the fork spring compressor, clamp and • Remove base. • Remove the spring collar. j A. Piston Rod Nut B. Spanner C. Right Front Fork Spring Preload Adjuster A. Spring
  • 2012 Kawasaki KX250F | Owners Manual - Page 128
    126 MAINTENANCE AND ADJUSTMENT the piston rod nut. • Unscrew Remove the spring guide and fork spring. • a drain pan under the right front fork and • Place drain fork oil. j NOTE żPump the right front fork outer tube and piston
  • 2012 Kawasaki KX250F | Owners Manual - Page 129
    MAINTENANCE AND ADJUSTMENT 127 the right front fork at the inverted position for • Hold more than 30 minutes to allow the fork oil to fully drain. the fork spring with the smaller end facing • Install upward. j A. Fork Spring B. Smaller End
  • 2012 Kawasaki KX250F | Owners Manual - Page 130
    128 MAINTENANCE AND ADJUSTMENT the fork piston rod puller (special • Using 57001-1298), pull up the piston rod. tool: the spring guide. • Install Install • down. the piston rod nut with the unthread side j A. Fork Piston Rod Puller, M10 × 1.0 (Special Tool: 57001-1298) B. Piston Rod A. Piston Rod
  • 2012 Kawasaki KX250F | Owners Manual - Page 131
    MAINTENANCE AND ADJUSTMENT 129 the piston rod nut onto the piston rod as • Screw shown in the figure. • Install the spring collar. j A. Spring Collar A. Piston Rod Nut B. Piston Rod C. 13 mm (0.51 in.) or more
  • 2012 Kawasaki KX250F | Owners Manual - Page 132
    130 MAINTENANCE AND ADJUSTMENT the clamps (special tool: 57001-1693) as • Install shown in the figure, and tighten the bolts. the holders of the fork spring compressor • Screw (special tool: 57001-1587). the right front fork tube on the base (special • Set tool: 57001-1753) as shown in the figure.
  • 2012 Kawasaki KX250F | Owners Manual - Page 133
    MAINTENANCE AND ADJUSTMENT 131 the compression shaft and screw the exten• Insert sion rod (special tool: 57001-1753). the other side compression shaft same • Set process. the extension rod (special tool: 57001 • Screw -1753) into the base (special tool: 57001-1753). j A. Extension Rod (Special
  • 2012 Kawasaki KX250F | Owners Manual - Page 134
    132 MAINTENANCE AND ADJUSTMENT the nuts. • Install Screw • out. in the nuts until the piston rod nut comes j A. Top Plug B. Piston Rod Nut C. Clearance (0.5 mm (0.02 in.) or more) A. Nuts the top plug clockwise. • Turn Check the clearance (0.5 mm (0.02 in.) or more) • between the lower end of the
  • 2012 Kawasaki KX250F | Owners Manual - Page 135
    MAINTENANCE AND ADJUSTMENT 133 the top plug into the spring collar to make • Push sure that it is securely installed. j A. Piston Rod Nut B. Top Plug C. Spanner D. Right Front Fork Spring Preload Adjuster A. Top Plug B. Spring Collar
  • 2012 Kawasaki KX250F | Owners Manual - Page 136
    134 MAINTENANCE AND ADJUSTMENT the fork spring compressor, clamp and • Remove base. the specified amount of fork oil into the right • Pour front fork outer tube. the O-ring on the top plug with a new one • Replace and apply specified fork oil to the O-ring. Standard Right Fork Oil Capacity Right
  • 2012 Kawasaki KX250F | Owners Manual - Page 137
    MAINTENANCE AND ADJUSTMENT 135 j A. Top Plug B. Right Front Fork Outer Tube C. Top Plug Wrench (Special Tool: 57001-1645) A. Left Front Fork Cylinder Unit B. Top Plug Wrench (Special Tool: 57001-1645) C. Torque Wrench the front fork tubes to the motorcycle. • Install Tighten front fork clamp
  • 2012 Kawasaki KX250F | Owners Manual - Page 138
    136 MAINTENANCE AND ADJUSTMENT wrench is fitted, and that of the octagonal hole of the wrench. żThis torque value (31 N·m (3.1 kgf·m, 23 ft·lb)) is applicable when you use a torque wrench whose length gives leverage of approximately 310 mm (12.2 in.) between the grip point to the center of the
  • 2012 Kawasaki KX250F | Owners Manual - Page 139
    clamp bolts to the spec• Tighten ified torque. Tightening Torque Right Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) the jack and stand supporting the motor• Remove cycle. tightening the clamp bolts on the right fork • Before leg, loosen the right front axle clamp bolts, and pump the forks
  • 2012 Kawasaki KX250F | Owners Manual - Page 140
    138 MAINTENANCE AND ADJUSTMENT WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an
  • 2012 Kawasaki KX250F | Owners Manual - Page 141
    MAINTENANCE AND ADJUSTMENT 139 Rear Suspension (UNI-TRAK®) This motorcycle's rear suspension system is called "UNI-TRAK®" and consists of a rear shock absorber unit, a swingarm, two lever rods and a lever. The operating characteristics of the UNI-TRAK® suspension are similar to those of the front
  • 2012 Kawasaki KX250F | Owners Manual - Page 142
    140 MAINTENANCE AND ADJUSTMENT Rebound Damping Adjuster Settings NOTICE Do not force the rebound damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. j NOTE żAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the
  • 2012 Kawasaki KX250F | Owners Manual - Page 143
    MAINTENANCE AND ADJUSTMENT 141 High Speed Compression Damping Adjuster Settings j A. Compression Damping Adjuster for High Speed B. Compression Damping Adjuster for Low Speed If the damping feels too soft or too stiff, adjust it in accordance with the following table. A. Seated Position (
  • 2012 Kawasaki KX250F | Owners Manual - Page 144
    142 MAINTENANCE AND ADJUSTMENT Low Speed Compression Damping Adjuster Settings NOTICE Do not force the compression damping force adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. j NOTE żAdjustment of the compression damping adjuster for the rear suspension
  • 2012 Kawasaki KX250F | Owners Manual - Page 145
    MAINTENANCE AND ADJUSTMENT 143 the hook wrench (special tool: 57001-1101), • Using turn the spring preload adjusting nut as required. Turning the adjusting nut down increases the spring preload. j A. Spring Preload Adjusting Nut B. Locknut C. Hook Wrenches (Special Tools: 57001-1101, 1539) A. Hook
  • 2012 Kawasaki KX250F | Owners Manual - Page 146
    144 MAINTENANCE AND ADJUSTMENT Rear Shock Absorber Spring K = 49 N/mm (K = 5.0 kgf/mm) K = 51 N/mm (K = 5.2 kgf/mm) K = 53 N/mm* (K = 5.4 kgf/mm) K = 55 N/mm (K = 5.6 kgf/mm) *: Standard Adjustable Range 125.8 a 135.8 mm (4.95 a 5.35 in.) 125.8 a 133.8 mm (4.95 a 5.27 in.) 125.8 a 139.5 mm (4.95 a
  • 2012 Kawasaki KX250F | Owners Manual - Page 147
    MAINTENANCE AND ADJUSTMENT 145 Wheels Tire Air Pressure Tire air pressure affects traction, handling, and tire life. Adjust the tire air pressure to suit track conditions and rider preference, but keep it close within the recommended range. To check the tire air pressure, remove the air valve cap,
  • 2012 Kawasaki KX250F | Owners Manual - Page 148
    146 MAINTENANCE AND ADJUSTMENT NOTE j żThe welding spot of the rim may show excessive runout. Disregard this when measuring rim runout. Rim Runout A. Bead Protector Nut Rim Runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout. The difference between
  • 2012 Kawasaki KX250F | Owners Manual - Page 149
    MAINTENANCE AND ADJUSTMENT 147 Hoses Inspection Check the brake and fuel hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart. Inspect the brake hose and fittings for deterioration, cracks and signs of leakage by bending or twisting
  • 2012 Kawasaki KX250F | Owners Manual - Page 150
    148 MAINTENANCE AND ADJUSTMENT Tightening Torques of Nuts and Bolts Location of nuts and bolts Before the first ride of each day of operation, check the tightness of the nuts and bolts shown below. Check also that all cotter pins are in place and in good condition. j 1. 2. 3. 4. 5. 6. 7. Front
  • 2012 Kawasaki KX250F | Owners Manual - Page 151
    MAINTENANCE AND ADJUSTMENT 149 j 1. Muffler Mounting Bolts 2. Muffler Clamp Bolt 3. Upper Engine Mounting/Bracket Bolts 4. Steering Stem Head Nut 5. Front Master Cylinder Clamp Bolts 6. Rear Master Cylinder Mounting Bolts 7. Rear Brake Disc Mounting Bolts 8. Rear Axle Nut 9. Rocker Arm Pivot Nut
  • 2012 Kawasaki KX250F | Owners Manual - Page 152
    150 MAINTENANCE AND ADJUSTMENT Torque table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. An overtightened nut or bolt
  • 2012 Kawasaki KX250F | Owners Manual - Page 153
    MAINTENANCE AND ADJUSTMENT 151 Fastener Chassis Air Cleaner Duct Clamp Screw Throttle Body Assy Holder Clamp Screw Muffler Clamp Bolt Muffler Mounting Bolts Engine Mounting Nut (Lower) Engine Bracket Nuts (Middle) Engine Mounting Nut (Middle) Engine Bracket Bolts (Upper) Engine Mounting Bolts (Upper
  • 2012 Kawasaki KX250F | Owners Manual - Page 154
    152 MAINTENANCE AND ADJUSTMENT Fastener Front Fork Clamp Bolts (Upper) Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Rocker Arm Pivot Nut Swingarm Pivot Shaft Nut Tie-Rod Mounting Nuts Handlebar Clamp Bolts Steering Stem Head Nut Rear Frame Mounting Bolts N·m 23 34 39 59 98 59 25
  • 2012 Kawasaki KX250F | Owners Manual - Page 155
    such as ammo- j WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around the
  • 2012 Kawasaki KX250F | Owners Manual - Page 156
    months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use non-abrasive products and apply them according to the instructions on the container. Leather, Vinyl, and Rubber If your motorcycle has leather accessories, special care must be taken. Use a leather cleaner
  • 2012 Kawasaki KX250F | Owners Manual - Page 157
    MAINTENANCE AND ADJUSTMENT 155 The sidewalls of tires and other rubber components should be treated with a rubber protectant to help prolong their useful life. Lubrication Lubricate the areas shown in the illustrations of this section with either motor oil or regular grease, after each race and
  • 2012 Kawasaki KX250F | Owners Manual - Page 158
    156 MAINTENANCE AND ADJUSTMENT Brake Pedal • Rear Rear Master • Kick Pedal Cylinder Joint Pin • Footpeg • • Shift Pedal j Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch Cable Throttle Cable • •
  • 2012 Kawasaki KX250F | Owners Manual - Page 159
    MAINTENANCE AND ADJUSTMENT 157 Cable Lubrication • • Apply grease to the following points: Clutch Inner Cable Upper End Throttle Inner Cable Upper End j A. Upper End Drive Chain Lubrication Lubricate the drive chain after riding through rain or on wet track, or any time that the chain appears
  • 2012 Kawasaki KX250F | Owners Manual - Page 160
    system and ignition system and ignition system parts are faulty. In case of serious troubles, the ECU stops the injection/ignition operation. Dealer Mode The FI indicator light emits service code(s) to show the problem(s) which the DFI system, and ignition system has at the moment of diagnosis. Self
  • 2012 Kawasaki KX250F | Owners Manual - Page 161
    MAINTENANCE AND ADJUSTMENT 159 the power supply harness (optional part: • Connect 26011-0246) to the capacitor lead connector of the the power supply harness (optional part: • Connect 26011-0246) to the 12 V battery as shown in the figure. main harness. j A. Connector • Disconnect the capacitor
  • 2012 Kawasaki KX250F | Owners Manual - Page 162
    light assy (optional part: • Keep 23016-0049) Y lead ground. the blinks of the light to read the service • Count code. Keep the lead ground until you finish read- j • ing the service code. To enter the self-diagnosis dealer mode, ground the self-diagnosis terminal for more than 2 seconds, and
  • 2012 Kawasaki KX250F | Owners Manual - Page 163
    number of problems, all the service codes can be stored and the display will begin • starting from thealowest number service codes in is open. If there is no problem, no code and unlight. For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the lowest
  • 2012 Kawasaki KX250F | Owners Manual - Page 164
    NOTE j żEven if the battery or the ECU are disconnected, or the problem is solved, all service codes remain in the ECU. Service Code Table Service Code 11 12 13 14 21 25 31 FI Indicator Light Problems Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring
  • 2012 Kawasaki KX250F | Owners Manual - Page 165
    NOTE żThe ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU (see Service Manual). żWhen no service code is displayed, the electrical parts of
  • 2012 Kawasaki KX250F | Owners Manual - Page 166
    164 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE NOTE żThis troubleshooting guide is not exhaustive and j does not give every possible cause for each problem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties. Starting failure or
  • 2012 Kawasaki KX250F | Owners Manual - Page 167
    TROUBLESHOOTING GUIDE 165 head warped • Cylinder Cylinder gasket • Decompression damaged trouble • Poor low-speed performance damaged • Cylinder Cylinder head warped • Cylinder gasket • Decompression damaged trouble • defective • ECU dragging • Brake Clutch • Engineslipping overheating • Engine
  • 2012 Kawasaki KX250F | Owners Manual - Page 168
    166 TROUBLESHOOTING GUIDE Fuel/air mixture incorrect: Air cleaner element clogged, poorly sealed, level too high • Engine Engine oil too high • Crankshaftviscosity worn or damaged • Drive chain bearing trouble • built up in combustion chamber • Carbon quality poor or type incorrect • Fuel plug type
  • 2012 Kawasaki KX250F | Owners Manual - Page 169
    TROUBLESHOOTING GUIDE 167 Lubrication inadequate: Engine oil level too low Engine oil quality Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift lever broken Pawl guide plate broken Shift return spring broken or weak Shift return spring pin loose Shift pawl broken Shift
  • 2012 Kawasaki KX250F | Owners Manual - Page 170
    168 TROUBLESHOOTING GUIDE Engine noise abnormal Knocking: Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating ECU defective chain, sprocket, chain guide worn • Camshaft Decompression spring broken • Flywheel magneto loose • Abnormal
  • 2012 Kawasaki KX250F | Owners Manual - Page 171
    TROUBLESHOOTING GUIDE 169 Rear shock absorber noise: Shock absorber damaged • Disc , tightened Exhaust smoke Excessively white: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: • Air cleaner element clogged • • Brownish:
  • 2012 Kawasaki KX250F | Owners Manual - Page 172
    170 TROUBLESHOOTING GUIDE Shock absorption unsatisfactory (suspension too soft): Front fork oil level insufficient and/or front fork leaking oil Front fork oil viscosity too low Front fork
  • 2012 Kawasaki KX250F | Owners Manual - Page 173
    POSITIONING on the machine. Before changing the suspension settings, test changing your riding posture or position to check whether it is the cause of the problem or not. It is a wise practice to adjust the suspension to suit the rider's strong points. If you are fast in the corners, adjust the
  • 2012 Kawasaki KX250F | Owners Manual - Page 174
    172 TUNING does not feel as "hard" in the later stage of fork travel. Fork Oil Capacity Effect on Fork Stroke Troubleshooting Improper Settings Listed below are some symptoms of improper suspension settings and the most likely means of correcting them. The proper settings can be achieved
  • 2012 Kawasaki KX250F | Owners Manual - Page 175
    TUNING 173 too soft • Springs Fork oil deteriorated • Rebound and/or compression damping improperly • adjusted. • Spring preload too soft Rear shock absorber improper adjustment symptoms Too Hard Suspension too stiff: Compression damping too high Spring too hard Hence, if the actual rider weighs
  • 2012 Kawasaki KX250F | Owners Manual - Page 176
    174 TUNING Suspension Tuning According the Type of Course Lower the front end slightly (Increase the amount of fork tube protrusion above the steering stem head by 5 mm Many Corners (0.20 in.).). This accelerates steering and enhances turning ability. Raise the front end slightly (Decrease the
  • 2012 Kawasaki KX250F | Owners Manual - Page 177
    and the rider's preferences. the fork oil capacity. • Decrease Use a softer spring, or decrease • preload. the spring NOTE Front and Rear Suspension Troubleshooting Front End Surges Downhill or During Acceleration Out of Corner The front suspension is too soft. Increase the compression damping or
  • 2012 Kawasaki KX250F | Owners Manual - Page 178
    176 TUNING the rebound damping. • Increase Decrease rear shock absorber spring preload. • Decrease the the compression damping. • Front and Rear Ends Bottom Off After a High-speed Jump (harsh bottoming occurs once or twice per lap) The front suspension is too soft. Increase the fork oil capacity.
  • 2012 Kawasaki KX250F | Owners Manual - Page 179
    TUNING 177 Gearing Selection of the Secondary Reduction Ratio (Rear Sprocket) Rear Sprocket Selection According to Course Conditions Fast Course Small sprocket Many Curves or Hills Sandy or Soft Ground Large sprocket it is difficult to set the machine so it is best • Since suited for all portions
  • 2012 Kawasaki KX250F | Owners Manual - Page 180
    178 TUNING Special Care According to Track Conditions dry, dusty conditions (such a volcanic ash or • In fine powdery dust), special care must be given to engine works hardest in muddy conditions • The and the radiator can become clogged with mud. Take care not to overheat the engine in these
  • 2012 Kawasaki KX250F | Owners Manual - Page 181
    the engine operation data in a personal computer (PC). KX FI Calibration Kit: Part No. - 99999-0334 For details, refer to the KX FI Calibration Kit manual.
  • 2012 Kawasaki KX250F | Owners Manual - Page 182
    engine, cylinder, piston and crankshaft bearings will be damaged. After riding, inspect the crankshaft big end. If the crankshaft big end is worn past the service limit, replace the crankshaft with a new one. Maintenance After Riding in the Rain or on a Muddy Course Apply grease to swingarm and rear
  • 2012 Kawasaki KX250F | Owners Manual - Page 183
    PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE 181 • Grease the throttle grip and control cables. Suggested Spare Parts and rear wheels • Front Shift pedal brake pedal • Brake lever,and lever, and holders • Throttle and clutch clutch cables • Handlebar • Front and rear fenders, side covers, and number
  • 2012 Kawasaki KX250F | Owners Manual - Page 184
    182 STORAGE STORAGE Before Storage When the motorcycle is to be stored for any length of time, it should be prepared for storage as follows. Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, then stop it and drain the engine oil. WARNING Gasoline is
  • 2012 Kawasaki KX250F | Owners Manual - Page 185
    STORAGE 183 After Storage the plastic bag from the muffler. • Remove Make sure the spark plug is tight. • the fuel tank with fuel. • Fill Check the points listed in the Daily Pre-Ride • Checksall section. a lubrication procedure in the Lubrication • Perform section. NOTE żFit the plug cap
  • 2012 Kawasaki KX250F | Owners Manual - Page 186
    184 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki motorcycle, please follow these Tread
  • 2012 Kawasaki KX250F | Owners Manual - Page 187
    WIRING DIAGRAM 185 WIRING DIAGRAM
  • 2012 Kawasaki KX250F | Owners Manual - Page 188
  • 1
  • 2
  • 3
  • 4
  • 5
  • 6
  • 7
  • 8
  • 9
  • 10
  • 11
  • 12
  • 13
  • 14
  • 15
  • 16
  • 17
  • 18
  • 19
  • 20
  • 21
  • 22
  • 23
  • 24
  • 25
  • 26
  • 27
  • 28
  • 29
  • 30
  • 31
  • 32
  • 33
  • 34
  • 35
  • 36
  • 37
  • 38
  • 39
  • 40
  • 41
  • 42
  • 43
  • 44
  • 45
  • 46
  • 47
  • 48
  • 49
  • 50
  • 51
  • 52
  • 53
  • 54
  • 55
  • 56
  • 57
  • 58
  • 59
  • 60
  • 61
  • 62
  • 63
  • 64
  • 65
  • 66
  • 67
  • 68
  • 69
  • 70
  • 71
  • 72
  • 73
  • 74
  • 75
  • 76
  • 77
  • 78
  • 79
  • 80
  • 81
  • 82
  • 83
  • 84
  • 85
  • 86
  • 87
  • 88
  • 89
  • 90
  • 91
  • 92
  • 93
  • 94
  • 95
  • 96
  • 97
  • 98
  • 99
  • 100
  • 101
  • 102
  • 103
  • 104
  • 105
  • 106
  • 107
  • 108
  • 109
  • 110
  • 111
  • 112
  • 113
  • 114
  • 115
  • 116
  • 117
  • 118
  • 119
  • 120
  • 121
  • 122
  • 123
  • 124
  • 125
  • 126
  • 127
  • 128
  • 129
  • 130
  • 131
  • 132
  • 133
  • 134
  • 135
  • 136
  • 137
  • 138
  • 139
  • 140
  • 141
  • 142
  • 143
  • 144
  • 145
  • 146
  • 147
  • 148
  • 149
  • 150
  • 151
  • 152
  • 153
  • 154
  • 155
  • 156
  • 157
  • 158
  • 159
  • 160
  • 161
  • 162
  • 163
  • 164
  • 165
  • 166
  • 167
  • 168
  • 169
  • 170
  • 171
  • 172
  • 173
  • 174
  • 175
  • 176
  • 177
  • 178
  • 179
  • 180
  • 181
  • 182
  • 183
  • 184
  • 185
  • 186
  • 187
  • 188