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Kawasaki KX250F - Service Manual

Manual is about: Motorcycle

Summary of KX250F -

  • Page 1

    Kx250f motorcycle service manual.

  • Page 3: Quick Reference Guide

    This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages back to match the black tab of the desired chapter num- ber 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 th...

  • Page 5: Kx250F

    Kx250f motorcycle service manual 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 divisi...

  • Page 6

    List of abbreviations a ampere(s) kds kawasaki diagnostic system abdc after bottom dead center km/h kilometers per hour ac alternating current l liter(s) ah ampere hour lb pound(s) atdc after top dead center led light emitting diode bbdc before bottom dead center m meter(s) bdc bottom dead center mi...

  • Page 7: Foreword

    Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...

  • Page 9: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 10

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions...

  • Page 11

    General information 1-3 before servicing storage of removed parts after all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspectio...

  • Page 12

    1-4 general information before servicing tightening torque incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tighten...

  • Page 13

    General information 1-5 before servicing ball bearing and needle bearing do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressu...

  • Page 14

    1-6 general information before servicing direction of engine rotation when rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical leads a two-color lead is i...

  • Page 15

    General information 1-7 model identification kx250zd left side view kx250zd right side view frame number engine number.

  • Page 16

    1-8 general information general specifications items kx250zd ∼ ze dimensions overall length 2 170 mm (85.43 in.) overall width 820 mm (32.3 in.) overall height 1 270 mm (50.00 in.) wheelbase 1 475 mm (58.07 in.) road clearance 330 mm (13.0 in.) seat height 945 mm (37.2 in.) curb mass: 106.2 kg (234....

  • Page 17

    General information 1-9 general specifications items kx250zd ∼ ze engine oil: type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 1.0 l (1.1 us qt) drive train primary reduction system: type gear reduction ratio 3.350 (67/20) clutch type wet multi disc, manual transm...

  • Page 18

    1-10 general information general specifications items kx250zd ∼ ze effective disc diameter: front 225 mm (8.86 in.) rear 215 mm (8.46 in.) specifications are subject to change without notice, and may not apply to every country..

  • Page 19

    General information 1-11 unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 21: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-3 torque and locking agent..................................................................................

  • Page 22

    2-2 periodic maintenance brakes.................................................................................................................................. 2-39 brake lever and pedal adjustment .................................................................................. 2-39 brake fluid ...

  • Page 23

    Periodic maintenance 2-3 periodic maintenance chart the maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Frequency operation each race or 2.5 hours every 3 races or 7.5 hours every 6 races or 15 hours every 12 races or 30 hours see page spark p...

  • Page 24

    2-4 periodic maintenance periodic maintenance chart frequency operation each race or 2.5 hours every 3 races or 7.5 hours every 6 races or 15 hours every 12 races or 30 hours see page wheels/tires - inspect • 2-34 rear sprocket - inspect † • 2-38 front fork - clean and inspect • 2-50 front fork oil ...

  • Page 25

    Periodic maintenance 2-5 torque and locking agent tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for ...

  • Page 26

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks camshaft chain tensioner cap bolt 20 2.0 15 camshaft chain tensioner mounting bolts 9.8 1.0 87 in·lb clutch right engine cover bolts 9.8 1.0 87 in·lb clutch cover bolts 9.8 1.0 87 in·lb oil filler plug 3.5 0.36...

  • Page 27

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear axle nut 108 11.0 79.7 final drive rear sprocket nuts 34 3.5 25 r engine sprocket nut (kx250ze) 78 8.0 57 brakes brake hose banjo bolts 25 2.5 18 front brake reservoir cap screws 1.5 0.15 13 in·lb front ma...

  • Page 28

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks piston rod locknut 37 3.8 27 r steering handlebar clamp bolts 25 2.5 18 al, 2t steering stem head nut 98 10.0 72 front fork clamp bolts (upper) 20 2.0 15 al, l steering stem nut 4.9 0.50 43 in·lb t handlebar ho...

  • Page 29

    Periodic maintenance 2-9 specifications item standard service limit fuel system (dfi) throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 2 050 ±50 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – – – cooling system coolant: type (recommended) permanent ty...

  • Page 30

    2-10 periodic maintenance specifications item standard service limit wheels/tires rim runout (with tire installed): axial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) tires air pressure (front/rear) 100 kpa (1.00 kgf/cm², 14 psi) – – ...

  • Page 31

    Periodic maintenance 2-11 specifications item standard service limit amount (left front fork): cylinder unit 330 ml (11.16 us oz.) cylinder unit oil level 115 ∼ 123 mm (4.53 ∼ 4.84 in.) outer tube 300 ±2.5 ml (10.14 ±0.085 us oz.) (adjustable range) 300 ∼ 340 ml (10.14 ∼ 11.50 us oz.) amount (right ...

  • Page 32

    2-12 periodic maintenance special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 fork piston rod puller, m12 × 1.25: 57001-1289 fork oil level gauge: 57001-1290 filler cap driver: 57001-1454 fork spring compressor: 57001-1587 jack attachment: 57001-1608 ...

  • Page 33

    Periodic maintenance 2-13 special tools fork spring compressor: 57001-1771 fork piston rod puller adapter: 57001-1791.

  • Page 34

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) fuel hose and connections inspection ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [a] or the hose burst. Remove the fuel tank (see fuel tank re- moval in the fu...

  • Page 35

    Periodic maintenance 2-15 periodic maintenance procedures throttle body cleaning • check the throttle bore for cleanliness as follows. ○ remove the throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter). ○ check the throttle bore [a] at the throttle valve for carbon dep...

  • Page 36

    2-16 periodic maintenance periodic maintenance procedures • pull the fuel hose joint [a] out of the delivery pipe. Warning fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. W...

  • Page 37

    Periodic maintenance 2-17 periodic maintenance procedures • remove the vinyl bag on each delivery pipe. • check that there are no flaws, burrs, and adhesion of foreign materials on each delivery pipe [a]. • replace the fuel hose with a new one. • run the fuel hose correctly (see cable, wire, and hos...

  • Page 38

    2-18 periodic maintenance periodic maintenance procedures • push and pull [a] the fuel hose joint back and forth more than two times and make sure it is locked and does not come off. Throttle body assy side [b] air cleaner side [c] warning leaking fuel can cause a fire or explosion resulting in seve...

  • Page 39

    Periodic maintenance 2-19 periodic maintenance procedures • check the idle speed, using the engine revolution tester [a] for high accuracy. If the idle speed is out of specified range, adjust it. Idle speed standard: 2 050 ±50 r/min (rpm) idle speed adjustment • start the engine and warm it up thoro...

  • Page 40

    2-20 periodic maintenance periodic maintenance procedures • remove: seat (see seat removal in the frame chapter) wing bolt [a] air cleaner element [b] • stuff a clean, lint-free towel into the air cleaner duct so no dirt is allowed to enter the throttle body assy. • wipe out the inside of the air cl...

  • Page 41

    Periodic maintenance 2-21 periodic maintenance procedures • apply grease to all connections and screw holes in the air cleaner housing and intake tract. • install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a complete seal. • i...

  • Page 42

    2-22 periodic maintenance periodic maintenance procedures coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • remove the right radiator shroud (see radiator shroud removal in the frame chapter). • lean the motorcycle slightly until the radiator ...

  • Page 43

    Periodic maintenance 2-23 periodic maintenance procedures coolant deterioration inspection • visually inspect the coolant. If 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...

  • Page 44

    2-24 periodic maintenance periodic maintenance procedures • bring the piston to the tdc of the compression stroke to inspect the valve clearance (the position at the end of the compression stroke), when the cam lobe faces outside of the camshaft. ○ place a wrench over the flywheel nut [a] and turn i...

  • Page 45

    Periodic maintenance 2-25 periodic maintenance procedures • clean the shim to remove any dust or oil. • measure the thickness of the removed shim [a]. • select a new shim thickness calculation as follows. A + b – c = d [a] present shim thickness [b] measured valve clearance [c] specified valve clear...

  • Page 46

    2-26 periodic maintenance periodic maintenance procedures • install the shim. ○ turn the marked side [a] to upside. ○ apply engine oil to the shim to keep the shim in place during camshaft installation. Notice do not put shim stock under the shim. This may cause the shim to pop out at high rpm, caus...

  • Page 47

    Periodic maintenance 2-27 periodic maintenance procedures • take a side-to-side and a front-to-back measurement as shown (total 6 measurements). ○ the cylinder wear is uneven in different places. 10 mm (0.39 in.) [a] 25 mm (0.98 in.) [b] 60 mm (2.36 in.) [c] cylinder inside diameter standard: 77.000...

  • Page 48

    2-28 periodic maintenance periodic maintenance procedures silencer wool replacement • remove: right side cover (see side cover removal in the frame chapter) muffler body cover bolts [a] muffler mounting bolt [b] • remove the muffler cover [a]. ○ tap the bracket [b] with a plastic mallet [c] to separ...

  • Page 49

    Periodic maintenance 2-29 periodic maintenance procedures clutch clutch operation inspection clutch lever (clutch cable) free play inspection • slide the clutch cable adjuster knob [a] out of place. • check that the clutch cable upper end [b] is fully seated in the adjusting bolt [c]. • install the ...

  • Page 50

    2-30 periodic maintenance periodic maintenance procedures • measure the thickness [a] of the friction and at several points with vernier calipers. Friction plate thickness standard: 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) service limit: 2.5 mm (0.10 in.) if they have worn past the service limit, replace ...

  • Page 51

    Periodic maintenance 2-31 periodic maintenance procedures • remove the engine oil drain bolt [a] from the bottom of the engine, and let the oil drain completely. Note ○ hold the motorcycle upright so that the oil may drain completely. • replace the drain bolt gasket with a new one. • install the dra...

  • Page 52

    2-32 periodic maintenance periodic maintenance procedures • remove the oil filter [a]. • replace the oil filter with a new one. • apply grease to the grommet [a]. • install the oil filter. ○ turn the grommet to inside. Notice inside out installation stop oil flow, causing engine seizure. • replace t...

  • Page 53

    Periodic maintenance 2-33 periodic maintenance procedures crankshaft/transmission crankshaft inspection • remove: cylinder head (see cylinder head removal in the en- gine top end chapter) cylinder (see cylinder removal in the engine top end chapter) piston (see piston removal in the engine top end c...

  • Page 54

    2-34 periodic maintenance periodic maintenance procedures tires inspection • remove any imbedded stones or other foreign particles from the tread. Repair or replace with a new one if necessary. • visually inspect the tire for cracks and cuts. Replace the tire, if any damage are noticed. ○ swelling o...

  • Page 55

    Periodic maintenance 2-35 periodic maintenance procedures • set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [a]. ○ the difference between the highest and lowest dial read- ings is the amount of runout. • set a dial gauge against the outer circumference of...

  • Page 56

    2-36 periodic maintenance periodic maintenance procedures • stretch the chain taut by hanging a 10 kg (22 lb) weight [a] on the chain. • measure the length of 20 links [b] on the straight part [c] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may ...

  • Page 57

    Periodic maintenance 2-37 periodic maintenance procedures drive chain slack adjustment • loosen the left and right chain adjuster locknuts [a]. • remove the cotter pin [b] and loosen the rear axle nut [c]. If the chain is too tight, back out the left and right chain adjusting bolts [d] evenly, and p...

  • Page 58

    2-38 periodic maintenance periodic maintenance procedures drive chain lubrication ○ the chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain. If the chain is especially dirty, it should be...

  • Page 59

    Periodic maintenance 2-39 periodic maintenance procedures brakes brake lever and pedal adjustment • slide the dust cover [a]. • adjust the brake lever to suit you. ○ loosen the adjuster locknut [b] and turn the adjuster [c] to either side. • after adjustment, tighten the locknut. Warning an improper...

  • Page 60

    2-40 periodic maintenance periodic maintenance procedures brake fluid level inspection • check the brake fluid level in the front or rear brake reser- voir [a] and the front or rear reservoir must be kept above the lower level line [b]. Note ○ hold the reservoir horizontal when checking brake fluid ...

  • Page 61

    Periodic maintenance 2-41 periodic maintenance procedures brake fluid change warning when working with the disc brake, observe the pre- cautions 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...

  • Page 62

    2-42 periodic maintenance periodic maintenance procedures note ○ the procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove: screws [a] reservoir cap [b] diaphragm • remove the rubber ca...

  • Page 63

    Periodic maintenance 2-43 periodic maintenance procedures • remove the clear plastic hose. • install the diaphragm and reservoir cap. • tighten: torque - front brake reservoir cap screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) • tighten the bleed valve, and install the rubber cap. Torque - caliper bleed val...

  • Page 64

    2-44 periodic maintenance periodic maintenance procedures rear master cylinder disassembly • remove the rear master cylinder (see rear master cylin- der removal in the brakes chapter). Note ○ do not remove the push rod clevis since removal re- quires brake pedal position adjustment. • remove the res...

  • Page 65

    Periodic maintenance 2-45 periodic maintenance procedures caliper rubber parts replacement front caliper disassembly • remove: front caliper (see caliper removal in the brakes chap- ter) brake pads (see brake pad removal in the brakes chapter) • separate the caliper holder [a] from the caliper [b]. ...

  • Page 66

    2-46 periodic maintenance periodic maintenance procedures • separate the caliper holder [a] from the caliper [b]. • remove the anti-rattle springs [c]. • using compressed air, remove the piston. ○ cover the caliper opening with a clean heavy cloth [a]. ○ remove the piston by lightly applying compres...

  • Page 67

    Periodic maintenance 2-47 periodic maintenance procedures • replace the fluid seal(s) [a] with new ones. ○ apply silicone grease to the fluid seal(s), and install them into the cylinder(s) by hand. • replace the dust seal(s) [b] with new ones. ○ apply brake fluid to the dust seal(s), and install the...

  • Page 68

    2-48 periodic maintenance periodic maintenance procedures • replace the friction boot [a] and dust boot [b] if they are damaged. • apply a thin coat of pbc (poly butyl cuprysil) grease to the caliper holder shafts [c] and holder holes (pbc is a special high-temperature, water-resistance grease). • a...

  • Page 69

    Periodic maintenance 2-49 periodic maintenance procedures front brake hose • remove: brake hose clamp bolts [a] brake hose clamps [b] rear brake hose • remove: bolts [a] caliper guard [b] screws [c] brake hose clamp [d] • remove: screws [a] brake hose clamp [b] rear master cylinder mounting bolts [c...

  • Page 70

    2-50 periodic maintenance periodic maintenance procedures suspension front fork inspection • visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tubes [a]. • holding the brake lever, pump the front fork down and up manually to check for smooth oper...

  • Page 71

    Periodic maintenance 2-51 periodic maintenance procedures • unscrew the left front fork cylinder unit [a] from the outer tube [b]. Special tool - top plug wrench, 50 mm [c]: 57001-1645 • slowly slide down the outer tube. • hold the left front fork tube [a] upside down over a clean container [b] and ...

  • Page 72

    2-52 periodic maintenance periodic maintenance procedures • compress the outer tube by hands and remove the ad- juster assembly from the axle holder part so that the lock- nut appear about 20 ∼ 30 mm (0.79 ∼ 1.2 in.). • hold the locknut [a] with a wrench [b] and remove the left front fork adjuster a...

  • Page 73

    Periodic maintenance 2-53 periodic maintenance procedures • holding the top plug wrench [a] with a vise, unscrew the left front fork base valve assembly [b] on the fork cylinder unit [c]. ○ use a box wrench [d]. Special tool - top plug wrench, 50 mm: 57001-1645 • pull out the left front fork base va...

  • Page 74

    2-54 periodic maintenance periodic maintenance procedures • hold the left front fork cylinder unit [a] upright with the piston rod fully stretched. • plug the oil hole [b] on the left front fork cylinder unit with finger. • pour the specified oil. Suspension oil - ss-19 (1 l) : 44091-0009 cylinder u...

  • Page 75

    Periodic maintenance 2-55 periodic maintenance procedures • with the piston rod [a] appear about 20 mm (0.79 in.) [b] from fully compressed, gently install the left front fork base valve assembly [c] slowly to the left front fork cylinder unit [d]. Note ○ plug the oil hole [e] on the left front fork...

  • Page 76

    2-56 periodic maintenance periodic maintenance procedures • check the compression damping force setting to the soft- est. • check the piston rod sliding surface for damage. • drain the extra oil from the left front fork cylinder unit oil hole [a]. • blow out the extra oil from the oil hole of the le...

  • Page 77

    Periodic maintenance 2-57 periodic maintenance procedures • there should be no oil leak from the base valve assembly part [a] or bottom of the cylinder [b]. If oil leaks from the base valve assembly part or bottom of the cylinder, replace the cylinder unit. • hold the left front fork cylinder unit o...

  • Page 78

    2-58 periodic maintenance periodic maintenance procedures • replace the left front fork adjuster assembly o-ring [a] with a new one and apply specified fork oil to it. • insert the push rod [b] into the piston rod [c]. • install the left front fork adjuster assembly [d] to the push rod. • slowly tur...

  • Page 79

    Periodic maintenance 2-59 periodic maintenance procedures • using the top plug wrench, unscrew the left front fork cylinder unit from the outer tube [a]. • slowly slide down the outer tube. • pour the specified fork oil into the left front fork outer tube. Suspension oil - ss-19 (1 l) : 44091-0009 o...

  • Page 80

    2-60 periodic maintenance periodic maintenance procedures • temporarily install the right front fork spring adjuster unit [a] to the outer tube [b]. Special tool - top plug wrench, 50 mm [c]: 57001-1645 • record the position of spring preload adjuster [a] and then turn [b] it to the hardest position...

  • Page 81

    Periodic maintenance 2-61 periodic maintenance procedures when not using the fork spring compressor (special tool: 57001-1771): • compress the outer tube by hands and install the top plug wrench [a] between the axle holder bottom [b] and locknut [c]. Special tool - top plug wrench, 50 mm: 57001-1645...

  • Page 82

    2-62 periodic maintenance periodic maintenance procedures • insert the holder bar [a] of the fork spring compressor (special tool: 57001-1587) to the axle hole and secure it with the holder [b] of the fork spring compressor (special tool: 57001-1771). Special tools - fork spring compressor: 57001-15...

  • Page 83

    Periodic maintenance 2-63 periodic maintenance procedures • hold the locknut [a] with a wrench [b] and remove the right front fork bottom plug [c]. Note ○ do not remove the locknut from the piston rod. The piston rod may slide into the inner tube. Notice when loosening the locknut, the threads of th...

  • Page 84

    2-64 periodic maintenance periodic maintenance procedures • tighten the locknut [a] fully. • install the fork piston rod puller adapter [a] to the threads on the fork piston rod puller [b]. Special tools - fork piston rod puller, m12 × 1.25: 57001 -1289 fork piston rod puller adapter: 57001-1791 • i...

  • Page 85

    Periodic maintenance 2-65 periodic maintenance procedures when not using the fork spring compressor (special tool: 57001-1771): • hold the axle holder part with a vise. ○ protect the axle holder part with a soft jaws or heavy cloth when using a vise. Warning if the axle holder is not securely clampe...

  • Page 86

    2-66 periodic maintenance periodic maintenance procedures • insert the holder bar [a] of the fork spring compressor (special tool: 57001-1587) to the axle hole and secure it with the holder [b] of the fork spring compressor (special tool: 57001-1771). Special tools - fork spring compressor: 57001-15...

  • Page 87

    Periodic maintenance 2-67 periodic maintenance procedures • replace the o-ring [a] on the right front fork bottom plug with a new one and apply specified fork oil to it. • slowly turn the right front fork bottom plug [a] clockwise until resistance is felt. Check the clearance between the locknut [b]...

  • Page 88

    2-68 periodic maintenance periodic maintenance procedures • hold the axle holder part with a vise. ○ protect the axle holder part with a soft jaws or heavy cloth when using a vise. Warning if the axle holder is not securely clamped, the front fork assembly may come out of the vise when com- pressed,...

  • Page 89

    Periodic maintenance 2-69 periodic maintenance procedures • holding the top plug wrench [a] with a vise, tighten the right front fork spring preload adjuster [b] on the right front fork spring adjuster unit [c] with a top plug wrench [d]. Special tools - top plug wrench, 50 mm: 57001-1645 top plug w...

  • Page 90

    2-70 periodic maintenance periodic maintenance procedures the torque of left front fork cylinder unit and right front fork spring adjuster unit are specified to 34 n·m (3.5 kgf·m, 25 ft·lb), however, when you use the top plug wrench [a], reduce the torque to 90% of the specified value [31 n·m (3.1 k...

  • Page 91

    Periodic maintenance 2-71 periodic maintenance procedures • adjust the gas reservoir damping adjusters [a] to the soft- est position. • remove the adjuster assembly [b] and pump the rear shock to drain the oil. • using the hand press, push the reservoir cap [a]. • remove: circlip [b] reservoir cap •...

  • Page 92

    2-72 periodic maintenance periodic maintenance procedures • visually inspect the piston [a], o-ring [b], and oil seal as- sembly [c]. If the piston, o-ring and oil seal assembly are badly scored, rusty or damaged, replace them. Piston rod assembly disassembly/assembly if necessary, disassembly and a...

  • Page 93

    Periodic maintenance 2-73 periodic maintenance procedures • wrap the threads [a] of the piston rod with tape. • remove the oil seal assembly [b]. • remove the o-ring [a] and spring [b]. • remove the rebound rubber [a] out of its groove [b]. • remove: collar [c] spring holder [d] oil seal [e] • remov...

  • Page 94

    2-74 periodic maintenance periodic maintenance procedures • remove: stopper [a] damper [b] damper holder [c] • inspect the piston rod sliding surface [a]. If the sliding surface is scratches or distortion, replace it. • hold the lower of the piston rod assembly in a vise with soft jaws or heavy clot...

  • Page 95

    Periodic maintenance 2-75 periodic maintenance procedures • remove the tape from piston rod. • install the piston assembly [a] so that the thick side of the stopper [b] faces downward. Note ○ be careful not to change the original positions. • install the new piston rod locknut [c]. • tighten: torque...

  • Page 96

    2-76 periodic maintenance periodic maintenance procedures • pull up the gas reservoir cap [a] against the circlip. 2.6 mm (0.1 in.) [b] warning pressurized nitrogen gas can explode out of the shock reservoir cap if the circlip is not properly in- stalled, allowing oil and internal parts to burst out...

  • Page 97

    Periodic maintenance 2-77 periodic maintenance procedures • remount the upper portion of the shock absorber in a vise with soft jaws or heavy cloth. • fill the specified oil [a] into the damping adjuster assem- bly hole. Suspension oil - ss-25 (1 l) : 45024-0001 rear shock absorber oil amount standa...

  • Page 98

    2-78 periodic maintenance periodic maintenance procedures • inject the nitrogen gas up to the 980 kpa (10.0 kgf/cm², 142 psi) pressure. Warning high pressure gas is dangerous and can explode, causing serious injury. To avoid injury, have a qual- ified mechanic pressurize the shock reservoir with nit...

  • Page 99

    Periodic maintenance 2-79 periodic maintenance procedures steering steering inspection • using the jack, raise the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • with the front wheel pointing straight ahead, alternately nudge each end of the handlebars. ○ ...

  • Page 100

    2-80 periodic maintenance periodic maintenance procedures • loosen the front fork clamp bolts (upper) [a] on both sides. • remove the steering stem head nut [b] and washer [c]. • remove the steering stem head [d]. • turn the steering stem nut [a] with the steering stem nut wrench [b] to obtain the p...

  • Page 101

    Periodic maintenance 2-81 periodic maintenance procedures frame frame inspection • clean the frame with steam cleaner. • visually inspect the frame and rear frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly ...

  • Page 102

    2-82 periodic maintenance periodic maintenance procedures general lubrication and cable inspection 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. Note ...

  • Page 103

    Periodic maintenance 2-83 periodic maintenance procedures cable inspection • with the cable disconnected at the both ends, the cable should move freely [a] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [b], or if the cable housing is kinked [c], re...

  • Page 104

    2-84 periodic maintenance periodic maintenance procedures if there are loose fasteners, retighten them to the spec- ified torque following the specified tightening sequence. Refer to the torque and locking agent section in this chapter for torque specifications. For each fastener, first loosen it by...

  • Page 105: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view........................................................................................................................ 3-4 dfi system...............................................................................................

  • Page 106

    3-2 fuel system (dfi) downstream injector removal.......................................................................................... 3-59 downstream injector installation....................................................................................... 3-59 downstream injector audible in...

  • Page 107

    Fuel system (dfi) 3-3 this page intentionally left blank..

  • Page 108

    3-4 fuel system (dfi) exploded view.

  • Page 109

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle pulley cover bolts 3.4 0.35 30 in·lb 2 throttle cable bolts 3.0 0.31 27 in·lb 3 throttle case mounting screws 3.8 0.39 34 in·lb 4 air cleaner duct clamp bolt 2.0 0.20 18 in·lb 5 delivery joint bolt 3.5 0.36 31...

  • Page 110

    3-6 fuel system (dfi) exploded view.

  • Page 111

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water temperature sensor 12 1.2 106 in·lb 2 gear position switch screws 2.9 0.30 26 in·lb l ad: apply adhesive. Eo: apply engine oil. G: apply grease. S: follow the specified tightening sequence. L: apply a non-permane...

  • Page 112

    3-8 fuel system (dfi) dfi system dfi system.

  • Page 113

    Fuel system (dfi) 3-9 dfi system 1. Fuel tank 2. Pressure regulator 3. Fuel pump 4. Intake air pressure sensor 5. Downstream injector 6. Upstream injector 7. Intake air temperature sensor 8. Air cleaner housing 9. Ignition coil 10. Vehicle-down sensor 11. Crankshaft sensor 12. Throttle sensor 13. Wa...

  • Page 114

    3-10 fuel system (dfi) dfi system dfi system wiring diagram.

  • Page 115

    Fuel system (dfi) 3-11 dfi system part names 1. Ecu 2. Self-diagnosis terminal 3. Throttle sensor 4. Intake air pressure sensor 5. Downstream injector 6. Upstream injector 7. Intake air temperature sensor 8. Water temperature sensor 9. Frame ground 1 10. Ignition coil 11. Spark plug 12. Frame ground...

  • Page 116

    3-12 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Power supply to ecu: r/w 2. Unused 3. Dfi setting data selection 1: w/bl 4. Downstream injector: bl/r 5. Unused 6. Ground for ecu: bk/y 7. Orange fi warning indicator light (led) [kx250zd]: bl/w orange launch cont...

  • Page 117

    Fuel system (dfi) 3-13 dfi parts location kawasaki diagnostic system connector [a] ecu [b] fi warning indicator light harness connector [c] (kx250zd) self-diagnosis terminal [d] orange launch control mode/fi warning indicator light (led) [a] (kx250ze) vehicle-down sensor [a] ignition coil [b] intake...

  • Page 118

    3-14 fuel system (dfi) dfi parts location capacitor [a] throttle sensor [b] water temperature sensor [c] gear position switch [d] crankshaft sensor [e] intake air temperature sensor [a] fuel pump [a].

  • Page 119

    Fuel system (dfi) 3-15 specifications item standard digital fuel injection system idle speed 2 050 ±50 r/min (rpm) throttle body assy: throttle valve single throttle valve bore 43 mm (1.69 in.) ecu: make keihin type digital memory type, with built in ic igniter, sealed with resin fuel pressure 294 k...

  • Page 120

    3-16 fuel system (dfi) specifications item standard throttle grip and cables throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.).

  • Page 121

    Fuel system (dfi) 3-17 special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 filler cap driver: 57001-1454 needle adapter set: 57001-1457 fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-1607 measuring adapter: 57001-1700...

  • Page 122

    3-18 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ connect these connectors until they click [a]. ○ never any of the dfi electrical connectors are discon- nected. The ecu memorizes...

  • Page 123

    Fuel system (dfi) 3-19 troubleshooting the dfi system outline kx250zd when an abnormality in the system occurs, the condition of the problem is stored in the memory of the ecu (elec- tronic control unit). With the engine stopped and conduct a self-diagnosis inspection, the service code is indicated ...

  • Page 124

    3-20 fuel system (dfi) troubleshooting the dfi system • when checking the dfi parts, use a digital meter which can be read two decimal place voltage or resistance. ○ the dfi part connectors [a] have seals [b], including the ecu. When measuring the input or output voltage with the connector joined, u...

  • Page 125

    Fuel system (dfi) 3-21 troubleshooting the dfi system • pull each connectors [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. Connect them securely. • check the wiring for continuity. ○ use the wiring d...

  • Page 126

    3-22 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 127

    Fuel system (dfi) 3-23 troubleshooting the dfi system sample diagnosis sheet rider name model engine no. Frame no. Date problem occurred environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: temperature □ hot, □ warm, □ cold, □ very cold, □ always problem fr...

  • Page 128

    3-24 fuel system (dfi) dfi system troubleshooting guide note ○ 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 in dfi system. ○ the ecu may be involved in t...

  • Page 129

    Fuel system (dfi) 3-25 dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Unstable (rough) idling: fue...

  • Page 130

    3-26 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) surge: unstable fuel pressure fuel pressure regulator trouble (inspect and replace fuel pump) or kinked fuel line (inspect and replace fuel pump) (see chapter 3). Upstream/downstream injector troubl...

  • Page 131

    Fuel system (dfi) 3-27 dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Knocking: fuel poor quality ...

  • Page 132

    3-28 fuel system (dfi) self-diagnosis self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu connected orange fi warning indicator light (led) (option)* goes on when dfi system and ignition syst...

  • Page 133

    Fuel system (dfi) 3-29 self-diagnosis • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c]. • the orange fi warning indicator light (led) will g...

  • Page 134

    3-30 fuel system (dfi) self-diagnosis self-diagnosis flow chart.

  • Page 135

    Fuel system (dfi) 3-31 self-diagnosis how to read service codes ○ service codes are shown by a series of long and short blinks of the orange fi warning indicator light (led) as shown below. ○ read 10th digit and unit digit as the orange fi warning indicator light (led) blinks. ○ when there are a num...

  • Page 136

    3-32 fuel system (dfi) self-diagnosis service code table service codes orange fi warning indicator light (led) problems 11 throttle sensor malfunction, wiring open or short 12 intake air pressure sensor malfunction, wiring open or short 13 intake air temperature sensor malfunction, wiring open or sh...

  • Page 137

    Fuel system (dfi) 3-33 self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi or the ignition system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 throttle sensor throttle sensor output voltage 0.58 ∼ 3....

  • Page 138

    3-34 fuel system (dfi) self-diagnosis note: (1) d-j method and α-n method: when the engine load is light like at idling or low speed, the ecu determines the injection quantity by calculating from the throttle vacuum (intake air pressure sen- sor output voltage) and engine speed (crankshaft sensor ou...

  • Page 139

    Fuel system (dfi) 3-35 throttle sensor (service code 11) the throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttl...

  • Page 140

    3-36 fuel system (dfi) throttle sensor (service code 11) • replace: throttle sensor screw [a] throttle sensor [b] o-ring [c] • apply engine oil to the new o-ring, and install it to the new throttle sensor. • engage the inner rotor groove [a] with the throttle shaft [b]. • insert the throttle sensor ...

  • Page 141

    Fuel system (dfi) 3-37 throttle sensor (service code 11) • adjust the sensor position so that the output voltage is within the specified voltage range. Throttle sensor output voltage standard: dc 0.58 ∼ 0.62 v if the input voltage reading shows other than 5 v, calculate a valid output voltage range ...

  • Page 142

    3-38 fuel system (dfi) throttle sensor (service code 11) • measure the input voltage with the engine stopped and with the connector joined. Input voltage standard: dc 4.75 ∼ 5.25 v • disconnect the power supply harness. If the reading is within the standard, check the output volt- age (see throttle ...

  • Page 143

    Fuel system (dfi) 3-39 throttle sensor (service code 11) • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • measure the output voltage with the engine stopped, and with the connector joined. Output voltage standard: dc 0.58 ∼ 0.62 v at idle throttle opening dc ...

  • Page 144

    3-40 fuel system (dfi) throttle sensor (service code 11) throttle sensor circuit 1. Ecu 2. Throttle sensor.

  • Page 145

    Fuel system (dfi) 3-41 intake air pressure sensor (service code 12) intake air pressure sensor removal notice never drop the intake air pressure sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose repl...

  • Page 146

    3-42 fuel system (dfi) intake air pressure sensor (service code 12) intake air pressure sensor input voltage inspection note ○ be sure the battery is fully charged. • disconnect the intake air pressure sensor connector and connect the measuring adapter [a] between these con- nectors. Main harness [b...

  • Page 147

    Fuel system (dfi) 3-43 intake air pressure sensor (service code 12) intake air pressure sensor output voltage inspection • measure the intake air pressure sensor output voltage in the same way as input voltage inspection. ○ disconnect the intake air pressure sensor connector and connect the measurin...

  • Page 148

    3-44 fuel system (dfi) intake air pressure sensor (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the intake air pressure sensor [a] and disconnect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the intake air pressure sensor. • temporarily...

  • Page 149

    Fuel system (dfi) 3-45 intake air pressure sensor (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: intake air pressure s...

  • Page 150

    3-46 fuel system (dfi) intake air pressure sensor (service code 12) intake air pressure sensor circuit 1. Ecu 2. Intake air pressure sensor.

  • Page 151

    Fuel system (dfi) 3-47 intake air temperature sensor (service code 13) intake air temperature sensor removal/instal- lation notice never drop the intake air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the rear frame with air cleaner housing ...

  • Page 152

    3-48 fuel system (dfi) intake air temperature sensor (service code 13) • measure the output voltage with the engine stopped and the connector joined. Output voltage standard: about dc 2.28 ∼ 3.43 v at intake air temperature 20°c (68°f) note ○ the output voltage changes according to the intake air te...

  • Page 153

    Fuel system (dfi) 3-49 intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Ecu 2. Intake air temperature sensor.

  • Page 154

    3-50 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant draining in the cooling system ch...

  • Page 155

    Fuel system (dfi) 3-51 water temperature sensor (service code 14) • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • measure the output voltage with the engine stopped and the connector joined. Output voltage standard: about dc 2.80 ∼ 2.97 v at water temperatur...

  • Page 156

    3-52 fuel system (dfi) water temperature sensor (service code 14) if the measurement is out of the range, replace the sensor. If the reading is within the standard, but the problem still exists, replace the ecu (see ecu removal/installation). Water temperature sensor circuit 1. Ecu 2. Water temperat...

  • Page 157

    Fuel system (dfi) 3-53 crankshaft sensor (service code 21) the crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft sensor removal/installation • refer to the stator coil removal/installation in the elec- trical system chapter. Cr...

  • Page 158

    3-54 fuel system (dfi) gear position switch (service code 25) gear position switch removal • remove: left radiator shroud (see radiator shroud removal in the frame chapter) shift pedal (see shift pedal removal in the crank- shaft/transmission chapter) engine sprocket cover and drive chain guide (see...

  • Page 159

    Fuel system (dfi) 3-55 gear position switch (service code 25) gear position switch inspection note ○ be sure the transmission mechanism is good condition. • remove the left radiator shroud (see radiator shroud re- moval in the frame chapter). • disconnect the gear position switch lead connector [a]....

  • Page 160

    3-56 fuel system (dfi) vehicle-down sensor (service code 31) when the motorcycle is down, the engine stops according to the condition of the below table. Engine speed time engine condition 2 500 rpm or less after 30 seconds stop 2 500 rpm or more after 3 seconds stop when the vehicle-down sensor is ...

  • Page 161

    Fuel system (dfi) 3-57 vehicle-down sensor (service code 31) • measure the input voltage with the engine stopped and with the connector joined. Input voltage standard: dc 4.75 ∼ 5.25 v if the reading is within the standard, check the output volt- age (see vehicle-down sensor output voltage inspec- t...

  • Page 162

    3-58 fuel system (dfi) vehicle-down sensor (service code 31) • hold the sensor vertically. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • measure the output voltage with the engine stopped and with the connector joined. ○ tilt the sensor 55 ∼ 75° or more [a...

  • Page 163

    Fuel system (dfi) 3-59 downstream injector (service code 41) notice never drop the downstream injector, especially on a hard surface. Such a shock to the downstream injector can damage it. Downstream injector removal • remove the throttle body assy (see throttle body assy removal). • remove the deli...

  • Page 164

    3-60 fuel system (dfi) downstream injector (service code 41) • fit the projections [a] on the delivery pipe to the hollows [b] of the throttle body assy. • tighten the delivery pipe mounting screw [a]. • install the removed parts (see appropriate chapters). Downstream injector audible inspection • r...

  • Page 165

    Fuel system (dfi) 3-61 downstream injector (service code 41) • connect a digital meter to the terminals in downstream injector [a]. • measure the downstream injector resistance. Downstream injector resistance connections: r/w terminal ←→ bl/r terminal standard: about 11.7 ∼ 12.3 Ω at 20°c (68°f) if ...

  • Page 166

    3-62 fuel system (dfi) downstream injector (service code 41) downstream injector output voltage inspection note ○ be sure the battery is fully charged. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. • refer to the self-diagnosis procedures, connect the 12 v battery to the...

  • Page 167

    Fuel system (dfi) 3-63 downstream injector (service code 41) downstream fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ place a piece of cloth around the fuel outlet pipe of fuel pump and delivery pipe of th...

  • Page 168

    3-64 fuel system (dfi) downstream injector (service code 41) downstream injector circuit 1. Ecu 2. Downstream injector 3. Frame ground 1 4. Capacitor.

  • Page 169

    Fuel system (dfi) 3-65 upstream injector (service code 42) notice never drop the upstream injector, especially on a hard surface. Such a shock to the upstream injector can damage it. Upstream injector removal • remove: rear frame with air cleaner housing (see rear frame removal in the frame chapter)...

  • Page 170

    3-66 fuel system (dfi) upstream injector (service code 42) • fit the projection [a] on the delivery pipe to the hollow [b] of the air cleaner housing. ○ face the connector side to left side. • apply a non-permanent locking agent to the threads of the delivery joint bolt [a]. • tighten: torque - deli...

  • Page 171

    Fuel system (dfi) 3-67 upstream injector (service code 42) upstream injector power supply voltage inspection note ○ be sure the battery is fully charged. • disconnect the upstream injector connector and connect the measuring adapter [a] between these connectors. Main harness [b] upstream injector [c...

  • Page 172

    3-68 fuel system (dfi) upstream injector (service code 42) upstream injector output voltage inspection note ○ be sure the battery is fully charged. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. • refer to the self-diagnosis procedures, connect the 12 v battery to the mai...

  • Page 173

    Fuel system (dfi) 3-69 upstream injector (service code 42) upstream injector fuel line inspection • remove: fuel hose (see rear frame removal in the frame chap- ter) ○ place a piece of cloth around the delivery pipe of air cleaner housing. • check the upstream injector fuel line for leakage as fol- ...

  • Page 174

    3-70 fuel system (dfi) upstream injector (service code 42) upstream injector circuit 1. Ecu 2. Upstream injector 3. Frame ground 1 4. Capacitor.

  • Page 175

    Fuel system (dfi) 3-71 fuel pump (service code 46) fuel pump removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any ...

  • Page 176

    3-72 fuel system (dfi) fuel pump (service code 46) • install the fuel pump [a] to the fuel tank. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • gradually tighten the fuel pump bolts evenly following the specified tightening sequence [1 ∼ 6]. • install the removed part...

  • Page 177

    Fuel system (dfi) 3-73 fuel pump (service code 46) • measure the operating voltage with engine stopped and with the connector joined. Operating voltage standard: battery voltage if the reading is not battery voltage, check the wiring for continuity (see fuel pump circuit). If the wiring is good, che...

  • Page 178

    3-74 fuel system (dfi) fuel pump (service code 46) fuel pump circuit 1. Ecu 2. Capacitor 3. Fuel pump 4. Frame ground 1.

  • Page 179

    Fuel system (dfi) 3-75 ignition coil (service code 51) ignition coil removal/installation • refer to the ignition coil removal/installation in the elec- trical system chapter. Ignition coil primary peak voltage inspection • refer to the ignition coil primary peak voltage check in the electrical syst...

  • Page 180

    3-76 fuel system (dfi) orange fi warning indicator light (led) (kx250ze) orange fi warning indicator light (led) inspection note ○ be sure the battery is fully charged. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • confirm that the orange fi warning indica...

  • Page 181

    Fuel system (dfi) 3-77 orange fi warning indicator light (led) (kx250ze) orange fi warning indicator light (led) circuit 1. Ecu 2. Orange fi warning indicator light (led) 3. Capacitor 4. Frame ground 1.

  • Page 182

    3-78 fuel system (dfi) ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle cannot clear the regulation. Ecu identification (kx250zd) part ...

  • Page 183

    Fuel system (dfi) 3-79 ecu • insert the slits [a] of the rubber protector to the ecu bracket. • connect the ecu connector [b]. Ecu power supply inspection • remove the number plate (see number plate removal in the frame chapter). • visually inspect the ecu connector. If the connector is clogged with...

  • Page 184

    3-80 fuel system (dfi) ecu • connect a digital meter [a] to the ecu connector [b] with the needle adapter set. Special tool - needle adapter set: 57001-1457 ecu power supply inspection connections: digital meter (+) → r/w lead (ecu terminal 1) digital meter (–) → battery (–) terminal standard: when ...

  • Page 185

    Fuel system (dfi) 3-81 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pum...

  • Page 186

    3-82 fuel system (dfi) fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure standard: 294 kpa (3.0 kgf/cm², 43 psi) with engine idling note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indic...

  • Page 187

    Fuel system (dfi) 3-83 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • disconnect the fuel hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. Warning fuel is flammable and explosive under cert...

  • Page 188

    3-84 fuel system (dfi) throttle grip and cable if the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the thro...

  • Page 189

    Fuel system (dfi) 3-85 throttle grip and cable • loosen the locknut [a] and bolts [b]. • remove the cables [c] from the throttle body assy. • free the tips [d] from the pulley. • pull out the cables from the frame. • lubricate the throttle cables (see lubrication in the peri- odic maintenance chapte...

  • Page 190

    3-86 fuel system (dfi) throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Throttle bore cleaning • refer to the throttle body cleaning in the periodic main- tenance chapter. Throttle body assy removal warning gasoline is extremely fla...

  • Page 191

    Fuel system (dfi) 3-87 throttle body assy throttle body assy disassembly • remove: throttle body assy (see throttle body assy removal) intake air pressure sensor [a] (see intake air pressure sensor removal) downstream injector [b] (see downstream injector re- moval) throttle sensor [c] (see throttle...

  • Page 192

    3-88 fuel system (dfi) air cleaner air cleaner housing removal • remove the rear frame (see rear frame removal in the frame chapter). • remove the air cleaner housing bolts [a]. • take the air cleaner housing off the rear frame. Air cleaner housing installation • assemble the air cleaner housing (se...

  • Page 193

    Fuel system (dfi) 3-89 fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and 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 p...

  • Page 194

    3-90 fuel system (dfi) fuel tank when removing with standard tip screwdriver: • insert the standard tip screwdriver [a] into the slit [b] on the joint lock [c]. • turn the driver to disconnect the joint lock. When removing with fingers: • open and push up [a] the joint lock [b] with your fingers. No...

  • Page 195

    Fuel system (dfi) 3-91 fuel tank • clean the pipe [a]. • cover the pipe and hose joint [b] with the vinyl bags [c] to keep them clean. Fuel tank installation • note the above warning (see fuel tank removal). • run the hoses correctly (see cable, wire, and hose rout- ing section in the appendix chapt...

  • Page 196

    3-92 fuel system (dfi) fuel tank • push and pull [a] the fuel hose joint back and forth more than two times, and make sure it is locked and does not come off. Warning leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is in- stalled correctly on the deliv...

  • Page 197: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................

  • Page 198

    4-2 cooling system exploded view.

  • Page 199

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water hose clamp screws 3.0 0.31 27 in·lb 2 water pipe bolt 9.8 1.0 87 in·lb 3 water pump cover bolts (l = 55 mm) 9.8 1.0 87 in·lb l 4 water pump impeller bolt 7.0 0.71 62 in·lb 5 water pump cover bolts (l = 30, 65 mm) 9....

  • Page 200

    4-4 cooling system specifications item standard recommended coolant type permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green mixed ratio soft water 50%, coolant 50% freezing point –35°c (–31°f) total am...

  • Page 201

    Cooling system 4-5 special tool bearing driver set: 57001-1129.

  • Page 202

    4-6 cooling system coolant coolant level inspection • refer to the coolant level inspection in the periodic main- tenance chapter. Coolant deterioration inspection • refer to the coolant deterioration inspection in the peri- odic maintenance chapter. Coolant draining warning coolant can be extremely...

  • Page 203

    Cooling system 4-7 coolant coolant filling notice use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the coo...

  • Page 204

    4-8 cooling system coolant cooling system pressure testing notice during pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kpa (1.25 kgf/cm², 18 psi). • remove the radiator cap, and install a cooling system pressure tester [a] and ad...

  • Page 205

    Cooling system 4-9 water pump water pump cover removal • remove the oil filter (see oil filter change in the periodic maintenance chapter). ○ drain the engine oil from the water pump cover. • drain the coolant (see coolant draining). • remove the water pipe bolt [a], and disconnect the water pipe [b...

  • Page 206

    4-10 cooling system water pump impeller removal • remove: water pump cover (see water pump cover removal) • remove the impeller bolt [a] and take out the impeller [b] and washer. Impeller installation • install the washer [a] and impeller [b]. • tighten: torque - water pump impeller bolt: 7.0 n·m (0...

  • Page 207

    Cooling system 4-11 water pump water pump gear installation • press in the water pump gear shaft [a] to the gear [b] until it is bottomed. • apply grease to the water pump gear shaft. • install the gear shaft from bearing side [c]. Notice be sure to apply grease to the water pump shaft when installi...

  • Page 208

    4-12 cooling system radiator radiator removal • drain the coolant (see coolant draining). • remove: radiator shrouds (see radiator shroud removal in the frame chapter) • remove the capacitor [a] (see capacitor removal in the electrical system chapter). • loosen: water hose clamp screws [b] • slide t...

  • Page 209

    Cooling system 4-13 radiator radiator installation • install: radiators washers clutch cable clamps [a] (left side) • tighten the radiator mounting bolts securely. • run the overflow hose and water hoses correctly (see cable, wire, and hose routing section in the appendix chapter). • tighten: torque...

  • Page 210

    4-14 cooling system radiator radiator cap inspection • check the top and bottom valve seals [a] of the radiator cap, and the condition of the valve spring [b]. If any one of them shows visible damage, replace the cap. • wet the top and bottom valve seals with water or coolant to prevent pressure lea...

  • Page 211: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-6 special tools and sealant ................. 5-9 cylinder head cover ......................... 5-12 cylinder head cover removal .... 5-12 ...

  • Page 212

    5-2 engine top end exploded view.

  • Page 213

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts 9.8 1.0 87 in·lb 2 camshaft cap bolts 9.8 1.0 87 in·lb mo, s 3 plug 20 2.0 15 l 4 cylinder head bolts (m10) 44 4.5 32 mo, r, s 5 auto-decompressor bolt 12 1.2 106 in·lb 6 cylinder head bolts (m6)...

  • Page 214

    5-4 engine top end exploded view.

  • Page 215

    Engine top end 5-5 exploded view g: apply grease. L: apply a non-permanent locking agent. R: replacement parts s: follow the specified tightening sequence. Ss: apply silicone sealant..

  • Page 216

    5-6 engine top end specifications item standard service limit camshafts cam height: exhaust 33.943 ∼ 34.057 mm (1.3363 ∼ 1.3408 in.) 33.84 mm (1.332 in.) intake 35.243 ∼ 35.357 mm (1.3875 ∼ 1.3920 in.) 35.14 mm (1.383 in.) camshaft journal/camshaft cap clearance 0.020 ∼ 0.062 mm (0.0008 ∼ 0.0024 in....

  • Page 217

    Engine top end 5-7 specifications item standard service limit valve seating surface: outside diameter: exhaust 24.6 ∼ 24.8 mm (0.969 ∼ 0.976 in.) – – – intake 30.6 ∼ 30.8 mm (1.205 ∼ 1.213 in.) – – – width: exhaust 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – intake 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – valv...

  • Page 218

    5-8 engine top end specifications valve stem diameter valve stem diameter [a] 45° [b] valve stem bend dial gauge [a].

  • Page 219

    Engine top end 5-9 special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston ring compressor grip: 57001-1095 piston ring compressor belt, 67 ∼ 79: 57001-1097 valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 45° - 32: 57001-1115...

  • Page 220

    5-10 engine top end special tools and sealant compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter, 60° - 25: 57001-1328 valve seat cutter holder, 4.5: 57001-1330 valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 valve seat cutter, 60° - 33: 57001-1334 filler cap d...

  • Page 221

    Engine top end 5-11 special tools and sealant valve guide driver attachment, f: 57001-1722 liquid gasket, tb1216b: 92104-1064.

  • Page 222

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) fuel hose (see fuel hose replacement in the periodic maintenance chapter) spark plug cap [a] cylinder head cover bolts [b] and washers cylinder head cover ...

  • Page 223

    Engine top end 5-13 cylinder head cover • install the cylinder head cover bolt washers with the metal side [a] upwards. • tighten: torque - cylinder head cover bolts [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the removed parts (see appropriate chapters)..

  • Page 224

    5-14 engine top end camshaft chain tensioner camshaft chain tensioner removal notice 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 tens...

  • Page 225

    Engine top end 5-15 camshafts camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] flywheel nut cap [b] special tool - filler cap driver: 57001-1454 • bring the piston to the tdc of the compression stroke. ○ place a wrench over the flywheel nut...

  • Page 226

    5-16 engine top end camshafts • remove: bolt [a] auto-decompressor [b] spring [c] camshaft installation • when installing the spring [a] on the auto-decompressor [b], put the spring end [c] onto the outside coil. • install the auto-decompressor [a] in the exhaust camshaft. • tighten: torque - auto-d...

  • Page 227

    Engine top end 5-17 camshafts • bring the piston to the tdc. ○ place a wrench over the flywheel nut [a] and turn it coun- terclockwise to align the tdc mark [b] with the center of the groove [c] of the inspection hole. • engage the camshaft chain with the camshaft sprockets. ○ align the timing marks...

  • Page 228

    5-18 engine top end camshafts • install the dowel pins [a] and positioning rings [b]. • apply molybdenum disulfide oil solution to the threads and seating surface of the camshaft cap bolts. • tighten all camshaft cap bolts evenly and lightly, and then tighten them with specified torque. ○ follow the...

  • Page 229

    Engine top end 5-19 camshafts camshaft chain removal • remove: camshafts (see camshaft removal) flywheel (see flywheel removal in the electrical sys- tem chapter) lower camshaft chain guide bolt [a] lower camshaft chain guide [b] • disengage the camshaft chain [c] from the crankshaft. Camshaft chain...

  • Page 230

    5-20 engine top end camshafts camshaft runout inspection • remove the camshafts (see camshaft removal). • set the camshaft in a camshaft alignment jig or on v blocks. • measure the runout with a dial gauge [a] at the specified place. If the runout exceeds the service limit, replace the camshaft. Cam...

  • Page 231

    Engine top end 5-21 cylinder head cylinder compression measurement • warm up the engine thoroughly. • stop the engine. • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) spark plug (see spark plug cleaning and inspection in the periodic maintenance chapter) • attach the com...

  • Page 232

    5-22 engine top end cylinder head cylinder head removal • drain the coolant (see coolant draining in the cooling system chapter). • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) cylinder head cover (see cylinder head cover re- moval) camshafts (see camshaft removal) exha...

  • Page 233

    Engine top end 5-23 cylinder head cylinder head installation • install the front camshaft chain guide. ○ fit the projection [a] in the groove [b] of the cylinder. ○ insert the guide end [c] into the recess of the crankcase securely. Note ○ in this figure, the magneto cover and flywheel has been remo...

  • Page 234

    5-24 engine top end cylinder head cylinder head warp inspection • refer to the cylinder head warp inspection in the peri- odic maintenance chapter..

  • Page 235

    Engine top end 5-25 valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head r...

  • Page 236

    5-26 engine top end valves valve installation notice do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. • visually inspect the valve surface. If the surface is damaged, replace the valve. • replace the oil seal [a] with a ne...

  • Page 237

    Engine top end 5-27 valves valve guide removal • remove: valve (see valve removal) oil seal spring seat • heat the area around the valve guide up to 120 ∼ 150°c (248 ∼ 302°f). Notice do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head in oil and heat ...

  • Page 238

    5-28 engine top end valves • ream the valve guide with valve guide reamer [a], even if the old guide is reused. ○ always rotate the reamer clockwise. Special tool - valve guide reamer, 4.5: 57001-1333 valve/valve guide clearance measurement (wobble method) if a small bore gauge is not available, ins...

  • Page 239

    Engine top end 5-29 valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. • measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 240

    5-30 engine top end valves seat cutter operation care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fai...

  • Page 241

    Engine top end 5-31 valves widened width [a] of engagement by machining with 45° cutter ground volume [b] by 32° cutter 32° [c] correct width [d] ground volume [e] by 60° cutter 60° [f] • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seati...

  • Page 242

    5-32 engine top end valves if the seat width is too wide, make the 60° [a] grind de- scribed 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° angle until the seat width is within the specified range [b]. ○ to make the 60°...

  • Page 243

    Engine top end 5-33 valves.

  • Page 244

    5-34 engine top end cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] • tap lightly up with a plastic mallet to separate the cylinder [c] from the crankcase. • remove the cylinder base gasket. Piston removal • re...

  • Page 245

    Engine top end 5-35 cylinder and piston note ○ the oil ring rails have no “top” or “bottom”. • install the oil ring expander [a] in the bottom piston ring groove so the ends [b] butt together. • install the oil ring steel rails on both sides of the oil ring expander. ○ spread the rail with your thum...

  • Page 246

    5-36 engine top end cylinder and piston • the piston ring openings must be positioned as shown. The openings of the oil ring steel rails must be 15 ∼ 20° of angle from the opening of the oil ring expander. Top ring [a] upper oil ring steel rail [b] oil ring expander [c] lower oil ring steel rail [d]...

  • Page 247

    Engine top end 5-37 cylinder and piston piston ring groove width inspection • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard: top 0.83 ∼ 0.85 mm (0.0327 ∼ 0.0335 in.) service limit: top 0.93 mm (0.037 in.) if any of the groove w...

  • Page 248

    5-38 engine top end cylinder and piston piston, piston pin, connecting rod wear inspection • visually inspect the snap rings [a] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston. • measure the dia...

  • Page 249

    Engine top end 5-39 throttle body assy holder throttle body assy holder removal • remove: cylinder head (see cylinder head removal) throttle body assy holder clamp screw [a] (loosen) throttle body assy holder [b] and holder clamp throttle body assy holder installation • install: throttle body assy h...

  • Page 250

    5-40 engine top end muffler warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler body removal • remove the right side cover (see side cover removal in the frame chapter). • loosen the muffler clamp bolt [a...

  • Page 251: Clutch

    Clutch 6-1 6 clutch table of contents exploded view........................................................................................................................ 6-2 specifications ................................................................................................................

  • Page 252

    6-2 clutch exploded view.

  • Page 253

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 right engine cover bolts 9.8 1.0 87 in·lb 2 clutch cover bolts 9.8 1.0 87 in·lb 3 oil filler plug 3.5 0.36 31 in·lb 4 clutch hub nut 98 10.0 72 r 5 clutch spring bolts 9.0 0.92 80 in·lb 6. Circlip equipped models cl: apply cable ...

  • Page 254

    6-4 clutch specifications item standard service limit clutch lever clutch lever free play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – clutch friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.5 mm (0.10 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.15 mm ...

  • Page 255

    Clutch 6-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129 clutch holder: 57001-1243.

  • Page 256

    6-6 clutch clutch lever and cable due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the periodic maintenance chart. Warning the engine and exhaust system get extremely hot during normal operation and can cause serious burn...

  • Page 257

    Clutch 6-7 clutch lever and cable • align the slit [a] of the adjusting nut to the slit [b] of the clutch lever. • free the clutch cable upper end from the clutch lever. • take the cable off the cable holder [a]. • take the cable lower end [b] off the clutch release lever [c]. Notice do not remove t...

  • Page 258

    6-8 clutch clutch cover and right engine cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: brake pedal bolt [a] brake pedal return spring [b] • remove the clutch cover bolts [a] and clutch cover [b]. Clutch cover installation •...

  • Page 259

    Clutch 6-9 clutch cover and right engine cover • remove: bolt [a] right engine guard [b] • remove: water pump cover (see water pump cover removal in the cooling system chapter) clutch cover bolts [a] right engine cover bolts [b] right engine cover [c] right engine cover installation • install the do...

  • Page 260

    6-10 clutch clutch cover and right engine cover • remove the vinyl tape from the kick shaft. • install: water pump cover (see water pump cover installation in the cooling system chapter) brake pedal (see brake pedal installation in the brakes chapter) oil filter (see oil filter change in the periodi...

  • Page 261

    Clutch 6-11 clutch clutch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] • remove: push rod holder assembly [a] steel ball friction plates [...

  • Page 262

    6-12 clutch clutch • install the clutch housing [a]. ○ turn the kickstarter idle gear and oil pump idle gear with a suitable tool [b] to fit in the clutch housing. • install: thrust washer [a] clutch hub [b] • hold the clutch hub with the clutch holder [a]. Special tool - clutch holder: 57001-1243 •...

  • Page 263

    Clutch 6-13 clutch • if a clutch part was replaced, install the standard adjusting washer (1.5 mm thickness) [a] of the push rod holder as- sembly, and check the release lever position as explained later procedure. • install the clutch spring plate and clutch springs. • tighten the clutch spring bol...

  • Page 264

    6-14 clutch clutch release shaft removal • remove: clutch (see clutch removal) clutch cable upper end (see clutch cable removal) • remove the tip [a] of the clutch cable. • pull out the release shaft assembly [b]. Release shaft installation • apply engine oil to the needle bearings [a]. • replace th...

  • Page 265

    Clutch 6-15 clutch friction plate/clutch housing clearance inspection • measure the clearance between the tangs [a] on the fric- tion plate and the fingers [b] of the clutch housing. If this clearance is excessive, the clutch will be noisy. If the clearance exceeds the service limit, replace the fri...

  • Page 267: Engine Lubrication System

    Engine lubrication system 7-1 7 engine lubrication system table of contents exploded view........................................................................................................................ 7-2 lubrication system chart ................................................................

  • Page 268

    7-2 engine lubrication system exploded view.

  • Page 269

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filter cap bolts 9.8 1.0 87 in·lb 2 piston oil nozzle 2.9 0.30 26 in·lb 3 breather fitting 15 1.5 11 4 oil pump idle gear shaft screws 5.9 0.60 52 in·lb l 5 oil pump mounting bolts 7.0 0.71 62 in·lb l 6 eng...

  • Page 270

    7-4 engine lubrication system lubrication system chart.

  • Page 271

    Engine lubrication system 7-5 lubrication system chart 1. Oil screen (scavenge) 2. Oil shower to transmission 3. Piston oil nozzle 4. Breather hose 5. Oil filter 6. Oil screen (feed) 7. Oil pump (scavenge) 8. Oil pump (feed) 9. Kick starter idle gear a: crank room oil b: transmission room oil c: blo...

  • Page 272

    7-6 engine lubrication system specifications item standard engine oil type castrol “power1 racing 4t” 5w-40 or api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, or 10w-50 capacity 0.75 l (0.79 us qt) (when filter is not removed) 0.80 l (0.85 us qt) (when filter is remov...

  • Page 273

    Engine lubrication system 7-7 special tools oil pressure gauge, 5 kgf/cm²: 57001-125 outside circlip pliers: 57001-144 oil pressure gauge adapter, m6 × 1.0: 57001-1664.

  • Page 274

    7-8 engine lubrication system engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter accordin...

  • Page 275

    Engine lubrication system 7-9 engine oil and oil filter oil filter replacement • refer to the oil filter replacement in the periodic main- tenance chapter. Oil screen cleaning and inspection oil screen (feed) • split the crankcase (see crankcase disassembly in the crankshaft/transmission chapter). •...

  • Page 276

    7-10 engine lubrication system engine oil and oil filter oil screen (scavenge) • remove the magneto cover (see magneto cover re- moval in the electrical system chapter). • remove the oil screen (scavenge) [a]. • clean the oil screen with a high flash-point solvent and remove any particles stuck to t...

  • Page 277

    Engine lubrication system 7-11 oil pump oil pump removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant draining in the cooling system chapter) • remove: brake pedal (see brake pedal removal in the brakes chapter) kick pedal (see kick pedal rem...

  • Page 278

    7-12 engine lubrication system oil pump • disassemble the oil pump assembly. Pins [a] oil pump cover [b] inner [c] and outer [d] rotors (feed) oil pump body [e] oil pump gear [f] oil pump installation • apply molybdenum disulfide grease to the shaft of the oil pump gear. • apply engine oil to the in...

  • Page 279

    Engine lubrication system 7-13 oil pump • apply molybdenum disulfide grease to the shaft of the oil pump idle gear [a]. • install the oil pump idle gear. • turn [b] the oil pump idle gear to check that the oil pump operates smoothly. • replace the circlip [c] with a new one. • install the new circli...

  • Page 280

    7-14 engine lubrication system oil pressure oil pressure measurement • remove the water pump cover bolt. • install the oil pressure gauge adapter [a] to the water pump cover. Special tool - oil pressure gauge adapter, m6 × 1.0: 57001-1664 • attach the oil pressure gauge [a]. Special tool - oil press...

  • Page 281: Engine Removal/installation

    Engine removal/installation 8-1 8 engine removal/installation table of contents exploded view........................................................................................................................ 8-2 special tools .......................................................................

  • Page 282

    8-2 engine removal/installation exploded view.

  • Page 283

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine mounting bolts 49 5.0 36 s 2 upper engine bracket bolts 29 3.0 21 s 3 middle engine bracket nuts 29 3.0 21 r, s 4 middle engine mounting nut 49 5.0 36 r, s 5 lower engine mounting nut 49 5.0 36 r...

  • Page 284

    8-4 engine removal/installation special tools jack: 57001-1238 jack attachment: 57001-1608.

  • Page 285

    Engine removal/installation 8-5 engine removal/installation engine removal • remove the engine guards. • place the jack under the frame to support the motorcycle. Special tools - jack: 57001-1238 jack attachment: 57001-1608 warning when the swingarm pivot shaft is removed the swingarm and rear wheel...

  • Page 286

    8-6 engine removal/installation engine removal/installation • remove: rear frame (see rear frame removal in the frame chapter) exhaust pipe (see exhaust pipe removal in the engine top end chapter) fuel tank (see fuel tank removal in the fuel system (dfi) chapter) radiators and water hoses (see radia...

  • Page 287

    Engine removal/installation 8-7 engine removal/installation • disconnect the water temperature sensor connector [a]. • remove the following parts on both sides: upper engine bracket bolts [b] upper engine mounting bolts [c] and nuts upper engine brackets [d] • remove: middle engine bracket bolts [a]...

  • Page 288

    8-8 engine removal/installation engine removal/installation • insert the swingarm pivot shaft from the right side. • install all engine brackets, bolts and nuts temporarily. ○ insert the following bolts from left side: middle engine mounting bolt [a] middle engine bracket bolts [b] lower engine moun...

  • Page 289: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view........................................................................................................................ 9-2 specifications ..............................................................................

  • Page 290

    9-2 crankshaft/transmission exploded view kx250zd.

  • Page 291

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 primary gear nut 98 10.0 72 lh, r 2 reed valve screws 7.0 0.71 62 in·lb 3 crankcase bearing retainer screws 15 1.5 11 l 4 piston oil nozzle 2.9 0.30 26 in·lb 5 crankcase bolts (l = 50 mm) 9.8 1.0 87 in·lb s 6 cra...

  • Page 292

    9-4 crankshaft/transmission exploded view kx250ze.

  • Page 293

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 primary gear nut 98 10.0 72 lh, r 2 reed valve screws 7.0 0.71 62 in·lb 3 crankcase bearing retainer screws 15 1.5 11 l 4 piston oil nozzle 2.9 0.30 26 in·lb 5 crankcase bolts (l = 50 mm) 9.8 1.0 87 in·lb s 6 cra...

  • Page 294

    9-6 crankshaft/transmission exploded view.

  • Page 295

    Crankshaft/transmission 9-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 kick ratchet guide bolt 8.8 0.90 78 in·lb l 2 kick pedal bolt 25 2.5 18 l 3 shift drum cam bolt 24 2.4 18 l 4 gear positioning lever nut 8.8 0.90 78 in·lb 5 ratchet plate bolt 9.8 1.0 87 in·lb l, s 6 ratchet plat...

  • Page 296

    9-8 crankshaft/transmission specifications item standard service limit crankshaft, connecting rod connecting rod big end: radial clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.00055 in.) 0.06 mm (0.0024 in.) side clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) 0.6 mm (0.02 in.) crankshaft runout tir 0.03 mm...

  • Page 297

    Crankshaft/transmission 9-9 special tools and sealant bearing puller: 57001-135 outside circlip pliers: 57001-144 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 crankcase splitting tool assembly: 57001-1362 gear holder, m2.0: 57001-1557 liquid gasket, tb1216: 92104-1063.

  • Page 298

    9-10 crankshaft/transmission crankcase crankcase disassembly • remove the engine from the frame (see engine removal in the engine removal/installation chapter). • set the engine on clean surface while parts are being re- moved. • remove: piston (see piston removal in the engine top end chap- ter) ri...

  • Page 299

    Crankshaft/transmission 9-11 crankcase • attach the crankcase splitting tool [a] to the left crankcase. ○ adjust the gap with suitable collars or nuts [b]. Special tool - crankcase splitting tool assembly: 57001 -1362 • tighten the center bolt to split the crankcase halves. ○ the front and rear port...

  • Page 300

    9-12 crankshaft/transmission crankcase • support the crankcase bearing boss with a suitable re- tainer [a]. • install the new bearing [b] with a press and the bearing driver set [c]. Special tool - bearing driver set: 57001-1129 notice support the crankcase bearing boss when the bear- ing is pressed...

  • Page 301

    Crankshaft/transmission 9-13 crankcase • press the new output shaft oil seal [a] so that the oil seal surface is flush with the crankcase surface. ○ turn the metal side to outside of the engine. • press the new shift shaft oil seal [b] so that the oil seal surface is flush with the crankcase surface...

  • Page 302

    9-14 crankshaft/transmission crankcase • press the new shift drum ball bearing [a] and new output shaft bearing [b] so that the sealed side [c] faces outside of the engine. Special tool - bearing driver set: 57001-1129 • install the right crankcase bearing retainers. ○ the right crankcase bearing re...

  • Page 303

    Crankshaft/transmission 9-15 crankcase • install: crankshaft (see crankshaft installation) transmission shafts (see transmission shaft installa- tion) • install the oil screen (feed) [a] so that the shorter pipe side faces upward. • position the connecting rod in bdc. • install the crankshaft jig [b...

  • Page 304

    9-16 crankshaft/transmission crankcase • install the gear positioning lever and shift drum cam (see external shift mechanism installation). • check to see that gears shift smoothly from 1st to 5th gear, and 5th to 1st while spinning the output shaft. • set the shift drum in the neutral position. • r...

  • Page 305

    Crankshaft/transmission 9-17 crankshaft crankshaft removal • split the crankcase (see crankcase disassembly). • remove the transmission shafts and shift drum (see transmission shaft removal). • using a press, remove the crankshaft [a] from the right crankcase. If the bearing stay on the crankshaft w...

  • Page 306

    9-18 crankshaft/transmission crankshaft • carefully align the oil passage hole in the right flywheel [a] with the one in the crankpin [b] at rebuilding of the crankshaft. • reassemble the crankshaft according to the standard tol- erances in specifications. ○ connecting rod bend, twist (see connectin...

  • Page 307

    Crankshaft/transmission 9-19 crankshaft • first correct the horizontal misalignment by striking the projecting crank half [a] with a plastic, soft lead, or brass hammer. • recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit. • next, correct the...

  • Page 308

    9-20 crankshaft/transmission crankshaft connecting rod bend inspection • remove the connecting rod. • select an arbor [a] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end. • select an arbor [b] of the same diameter as the piston pin and ...

  • Page 309

    Crankshaft/transmission 9-21 transmission transmission shaft removal • split the crankcase (see crankcase disassembly). • pull out the shift rods [a], and remove the shift forks [b]. • remove the shift drum [c]. • pull out the drive shaft [d] and output shaft [e] together. Transmission shaft install...

  • Page 310

    9-22 crankshaft/transmission transmission transmission shaft assembly • apply engine oil liberally to the transmission shaft, gears and bearings. • replace any circlips that were removed with new ones. ○ always install the circlips [a] so that the opening [b] is aligned with a spline groove [c], and...

  • Page 311

    Crankshaft/transmission 9-23 transmission kx250zd 1. Circlip (small) 2. Toothed washer 3. Circlip (large) 4. Ball bearing (left crankcase, one side sealed) 5. 2nd gear (16t) 6. Bushing 7. 4th gear (17t) 8. 3rd gear (18t) 9. 5th gear (22t) 10. Drive shaft (1st gear, 14t) 11. Ball bearing (right crank...

  • Page 312

    9-24 crankshaft/transmission transmission kx250ze 1. Circlip (small) 2. Toothed washer 3. Circlip (large) 4. Ball bearing (left crankcase, one side sealed) 5. 2nd gear (16t) 6. Bushing 7. 4th gear (17t) 8. 3rd gear (18t) 9. 5th gear (22t) 10. Drive shaft (1st gear, 14t) 11. Ball bearing (right crank...

  • Page 313

    Crankshaft/transmission 9-25 transmission shift fork/gear groove wear inspection • measure the thickness [a] of the shift fork ears, and mea- sure the width [b] of the gear grooves (with which the fork engages). Shift fork ear thickness standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) service limit: 4.8 m...

  • Page 314

    9-26 crankshaft/transmission primary gear primary gear removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) • temporarily install the clutch housing [a], clutch hub [b], toothed washer and clutch hub nut [c]. • ...

  • Page 315

    Crankshaft/transmission 9-27 external shift mechanism shift pedal removal • remove: shift pedal bolt [a] shift pedal [b] shift pedal installation • install the shift pedal so that the slit [a] on the pedal aligns with the punch mark [b] on the shift shaft. • tighten: torque - shift pedal bolt [c]: 9...

  • Page 316

    9-28 crankshaft/transmission external shift mechanism • remove: pin [a] gear positioning lever [b] collar [c] spring [d] external shift mechanism installation • install: pin [a] spring [b] collar [c] gear positioning lever [d] washer • tighten: torque - gear positioning lever nut: 8.8 n·m (0.90 kgf·...

  • Page 317

    Crankshaft/transmission 9-29 external shift mechanism • install the shift ratchet assembly [a] and ratchet plate [b] as a set. • apply a non-permanent locking agent to the ratchet plate screw and bolt. • tighten: torque - ratchet plate screw [c]: 15 n·m (1.5 kgf·m, 11 ft·lb) ratchet plate bolt [d]: ...

  • Page 318

    9-30 crankshaft/transmission external shift mechanism • check the shift ratchet assembly for any damage. If the ratchet [a], pawls [b], pins [c] or springs [d] are damaged in any way, replace them. • visually inspect the shift drum cam [a]. If it is badly worn or if it shows any damage, replace it. ...

  • Page 319

    Crankshaft/transmission 9-31 kickstarter kick pedal removal • remove: kick pedal bolt [a] and washer kick pedal assy [b] kick pedal installation • install the kick pedal assy. ○ put the pedal end [a] near the cylinder head cover mating surface [b]. • apply a non-permanent locking agent to the thread...

  • Page 320

    9-32 crankshaft/transmission kickstarter kick shaft removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) kickstarter idle gear [a] • pull the spring end [b] out of the hole. • turn the kick shaft counterclockwis...

  • Page 321

    Crankshaft/transmission 9-33 kickstarter • apply molybdenum disulfide grease [a] to the kick gear, ratchet gear and kick shaft. • replace the circlips that were removed with new ones. Special tool - outside circlip pliers: 57001-144 note ○ when assembling the ratchet gear [a] onto the kick shaft [b]...

  • Page 322

    9-34 crankshaft/transmission bearings/oil seals bearing replacement notice do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the absence of the above mentioned tools, satisfa...

  • Page 323

    Crankshaft/transmission 9-35 bearings/oil seals • inspect the needle bearings. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the conditi...

  • Page 325: Wheels/tires

    Wheels/tires 10-1 10 wheels/tires table of contents exploded view........................................................................................................................ 10-2 specifications .................................................................................................

  • Page 326

    10-2 wheels/tires exploded view.

  • Page 327

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples not less than 2.2 not less than 0.22 not less than 19 in·lb 2 front axle nut 78 8.0 58 3 front axle clamp bolts 20 2.0 15 al, s 4 rear axle nut 108 11.0 79.7 al: tighten the two clamp bolts alternately two ti...

  • Page 328

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim size: front 21 × 1.60 – – – rear 19 × 1.85 – – – rim runout: axial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (...

  • Page 329

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover head, 25 × 28: 57001-1346 bearing remover shaft, 13: 57001-1377 jack attachment: 57001-1608.

  • Page 330

    10-6 wheels/tires wheels (rims) front wheel removal • remove the axle nut [a]. • loosen the axle clamp bolts [b] on both sides. • raise the front wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • pull out the axle and remove the wheel. • remove the collar...

  • Page 331

    Wheels/tires 10-7 wheels (rims) • pump the front fork up and down [a] 4 or 5 times to align both fork positions. Note ○ put a block [b] in front of the wheel to stop moving. ○ do not apply the front brake. • tighten: torque - front axle clamp bolts (right): 20 n·m (2.0 kgf·m, 15 ft·lb) note ○ tighte...

  • Page 332

    10-8 wheels/tires wheels (rims) • remove the cotter pin [a], rear axle nut [b] and washer [c]. • pull out the axle [d], and remove the chain adjuster [e] on both sides. • disengage the drive chain from the rear sprocket. • remove the rear wheel. • remove the collars [a] with caps [b] on both sides. ...

  • Page 333

    Wheels/tires 10-9 wheels (rims) • install the rear wheel. • engage the drive chain with the rear sprocket. • install the chain adjusters on the swingarm. Adjuster [a] (left side) flat adjuster [b] (right side) • insert the axle from left side, and tighten the axle nut. Torque - rear axle nut: 108 n·...

  • Page 334

    10-10 wheels/tires wheels (rims) rim installation position • when installing the rim, set the rim following position. ○ the distance [a] from the brake disc seating surface [b] of the front hub [c] to left end of the front rim [d] should be as follows. View from front [e] distance: 26.8 ±0.5 mm (1.0...

  • Page 335

    Wheels/tires 10-11 tires air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter. Tire removal • remove the wheel (see front/rear wheel removal). Notice do not lay the wheel directly on the ground with the disc facing down. This can ...

  • Page 336

    10-12 wheels/tires tires • lubricate the suitable tire irons [a] and rim protectors [b] with soap and water solution or rubber lubricant. Special tool - rim protector: 57001-1063 • step on the side of the tire opposite air valve, and pry the tire off the rim with the tire irons protecting the rim wi...

  • Page 337

    Wheels/tires 10-13 tires • tighten the bead protector nut [a], air valve nut [b] and air valve cap [c]. • adjust the tire air pressure to the specified pressure (see air pressure inspection/adjustment in the periodic main- tenance chapter)..

  • Page 338

    10-14 wheels/tires hub bearing front hub bearing removal • remove: front wheel (see front wheel removal) grease seals [a] • use the bearing remover to remove the hub bearings [a]. Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place wooden bloc...

  • Page 339

    Wheels/tires 10-15 hub bearing • using a suitable bar [a], tap the around of the bearing inner race evenly to remove the bearings [b]. Hub bearing installation • before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the ...

  • Page 340

    10-16 wheels/tires hub bearing hub bearing inspection since the hub bearings are made to extremely close tol- erances, the clearance cannot normally be measured. Note ○ do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones. • turn each ...

  • Page 341: Final Drive

    Final drive 11-1 11 final drive table of contents exploded view........................................................................................................................ 11-2 specifications ...................................................................................................

  • Page 342

    11-2 final drive exploded view.

  • Page 343

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 r 2 engine sprocket nut (kx250ze) 78 8.0 57 3. Kx250zd ho: apply heavy oil. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 344

    11-4 final drive specifications item standard service limit drive chain chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make daido – – – type did 520dma4 – – – link 114 links – – – sprocket rear sprocket warp ti...

  • Page 345

    Final drive 11-5 special tool outside circlip pliers: 57001-144.

  • Page 346

    11-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection • check that the notch [...

  • Page 347

    Final drive 11-7 drive chain drive chain installation • fit the drive chain onto the sprockets. ○ place the drive chain ends on the rear sprocket. • install the master link [a] from the wheel side. • install the link plate [a] so that the mark faces out. • install the clip [b] so that the closed end...

  • Page 348

    11-8 final drive sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] kx250zd • remove: circlip [a] special tool - outside circlip pliers: 57001-144 • remove the engine sprocket [b] from the drive chain [c]. Kx250ze • flatten the...

  • Page 349

    Final drive 11-9 sprockets kx250ze • engage the drive chain [a] to the engine sprocket [b] and install the engine sprocket on the output shaft. • replace the sprocket washer with a new one. • install the sprocket washer and sprocket nut. • tighten: torque - engine sprocket nut: 78 n·m (8.0 kgf·m, 57...

  • Page 351: Brakes

    Brakes 12-1 12 brakes table of contents exploded view........................................................................................................................ 12-2 specifications .............................................................................................................

  • Page 352

    12-2 brakes exploded view.

  • Page 353

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 front brake reservoir cap screws 1.5 0.15 13 in·lb 3 front master cylinder clamp bolts 8.8 0.90 78 in·lb s 4 brake lever pivot bolt 5.9 0.60 52 in·lb si 5 brake lever pivot bolt locknut 5.9 0.6...

  • Page 354

    12-4 brakes exploded view.

  • Page 355

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear brake reservoir cap bolts 1.5 0.15 13 in·lb 3 rear master cylinder mounting bolts 9.8 1.0 87 in·lb 4 rear master cylinder push rod locknut 17 1.7 13 5 brake pedal bolt 25 2.5 18 g, l 6 rea...

  • Page 356

    12-6 brakes specifications item standard service limit brake lever lever free play adjustable (to suit rider) – – – brake fluid grade: front dot3 or dot4 – – – rear dot3 or dot4 – – – brake pads lining thickness: front 4.0 mm (0.16 in.) 1 mm (0.04 in.) rear 6.4 mm (0.25 in.) 1 mm (0.04 in.) brake di...

  • Page 357

    Brakes 12-7 special tools jack: 57001-1238 jack attachment: 57001-1608.

  • Page 358

    12-8 brakes brake lever, brake pedal brake lever play adjustment • refer to the brake lever and pedal adjustment in the periodic maintenance chapter. Brake pedal position adjustment • refer to the brake lever and pedal adjustment in the periodic maintenance chapter. Brake pedal removal • remove: cot...

  • Page 359

    Brakes 12-9 brake lever, brake pedal • replace the cotter pin with a new one. • install the joint pin, washer and new cotter pin. • bend the ends [a] of the cotter pin. • check the brake pedal position (see brake lever and pedal adjustment in the periodic maintenance chapter)..

  • Page 360

    12-10 brakes brake fluid warning when working with the disc brake, observe the pre- cautions 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 th...

  • Page 361

    Brakes 12-11 brake fluid brake line bleeding 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 ...

  • Page 362

    12-12 brakes brake fluid • bleed the brake line and caliper as follows: ○ repeat this operation until no more air can be seen com- ing out into the clear plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve wh...

  • Page 363

    Brakes 12-13 caliper caliper removal front brake • loosen the brake pad pin [a] before the caliper [b] re- moval if the caliper is to be disassembled. • loosen the banjo bolt [c] so as not to spill brake fluid. Note ○ if the caliper is to be disassembled after removal and compressed air is not avail...

  • Page 364

    12-14 brakes caliper caliper installation • install the brake pad if it was removed (see brake pad installation). Front brake • install the caliper and tighten the bolts. Torque - front caliper mounting bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) rear brake • install the rear wheel and caliper (see rear whe...

  • Page 365

    Brakes 12-15 caliper fluid seal damage inspection the fluid seal(s) [a] around the piston maintains the proper pad/disc clearance. If this seal is not in good condi- tion, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. • replace the fluid seal...

  • Page 366

    12-16 brakes caliper caliper piston and cylinder damage inspection • visually inspect the piston(s) [a] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Front caliper [b] rear caliper [c] caliper holder shaft wear inspection the caliper body must slide...

  • Page 367

    Brakes 12-17 brake pad brake pad removal front brake • remove the pad pin [a]. • remove the piston side pad [b]. • push the caliper holder toward the piston, and then re- move another pad [c]. Rear brake • remove: pad pin plug [a] • remove the pad pin [a]. • remove the piston side pad [b]. • push th...

  • Page 368

    12-18 brakes brake pad • tighten the brake pad pin. Torque - brake pad pin: 17 n·m (1.7 kgf·m, 13 ft·lb) rear brake pad pin plug: 2.4 n·m (0.24 kgf·m, 21 in·lb) • check the brake for good braking power, no brake drag, and no fluid leakage. Warning after servicing, it takes several applications of th...

  • Page 369

    Brakes 12-19 master cylinder notice brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely washed up immediately. Front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose upper end [b] from the master cylinder [c]. ○ when removin...

  • Page 370

    12-20 brakes master cylinder • the master cylinder clamp must be installed with the ar- row mark [a] upward. • tighten the upper clamp bolt [b] first, and then the lower clamp bolt [c]. ○ there will be a gap at the lower mating surface of the clamp after tightening. Torque - front master cylinder cl...

  • Page 371

    Brakes 12-21 master cylinder • replace the cotter pin with a new one. • install the joint pin, washer and new cotter pin. • bend the ends [a] of the cotter pin. • check the brake pedal position (see brake lever and pedal adjustment in the periodic maintenance chapter). • bleed the brake line (see br...

  • Page 372

    12-22 brakes master cylinder master cylinder 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 the outside of each piston [b]. If a master cylinder or piston show...

  • Page 373

    Brakes 12-23 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • remove the mounting bolts, and take off the disc. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • apply a non-permanent ...

  • Page 374

    12-24 brakes brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hoses and connections inspection in the periodic maintenance chapter..

  • Page 375: Suspension

    Suspension 13-1 13 suspension table of contents exploded view........................................................................................................................ 13-2 specifications .....................................................................................................

  • Page 376

    13-2 suspension exploded view.

  • Page 377

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air pressure relief screws 1.3 0.13 12 in·lb 2 left front fork base valve assembly 30 3.1 22 3 front fork clamp bolts (upper) 20 2.0 15 al, l 4 front fork clamp bolts (lower) 22 2.2 16 al 5 right front fork spring preload ad...

  • Page 378

    13-4 suspension exploded view.

  • Page 379

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber mounting nut (upper) 39 4.0 29 r 2 rear shock absorber mounting nut (lower) 34 3.5 25 r 3 tie-rod mounting nuts 59 6.0 44 r 4 swingarm pivot shaft nut 98 10.0 72 r 5 rocker arm pivot nut 59 6.0 44 r 6 gas...

  • Page 380

    13-6 suspension specifications item standard service limit front fork kx250zd air pressure atmospheric pressure – – – rebound damping adjustment (left fork only) (from the seated position adjuster turned fully clockwise) 10 clicks counterclockwise (eur, br, th) 12 clicks counterclockwise (adjustable...

  • Page 381

    Suspension 13-7 specifications item standard service limit outer tube 300 ±2.5 ml (10.14 ±0.085 us oz.) (adjustable range) 300 ∼ 340 ml (10.14 ∼ 11.50 us oz.) amount (right front fork) 223 ±2.5 ml (7.54 ±0.085 us oz.) (adjustable range) 218 ∼ 366 ml (7.37 ∼ 12.37 us oz.) fork spring free length (rig...

  • Page 382

    13-8 suspension special tools oil seal & bearing remover: 57001-1058 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 fork oil seal driver, 48: 57001-1509 hook wrench t=3.2 r37: 57001-1539 jack attachment: 57001-1608.

  • Page 383

    Suspension 13-9 front fork air pressure the standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during operation. Re- lease air pressure prior to each race through the air pres- sure relief screw....

  • Page 384

    13-10 suspension front fork seated position [a]: adjuster turned fully clockwise. Compression damping adjuster setting standard: 8 clicks [b] (kx250zd) (eur, br, th) 10 clicks (kx250zd) 9 clicks (kx250ze) softer (counterclockwise) [c] harder (clockwise) [d] *: although you can turn the adjuster beyo...

  • Page 385

    Suspension 13-11 front fork seated position [a]: adjuster turned fully counterclock- wise. Spring preload adjuster setting standard: 15 clicks [b] (kx250zd) (eur, br, th) 7 clicks (kx250zd) 8 clicks (kx250ze) (eur, br, th) 6 clicks (kx250ze) harder (clockwise) [c] softer (counterclockwise) [d] *: al...

  • Page 386

    13-12 suspension front fork • pull out the front fork downward with a twisting motion [a]. Front fork installation • install the front fork. ○ the length [a] between the upper end [b] of the outer tube and steering stem head [c] is 5 mm (0.20 in.). • run the cables and hose according to the cable, w...

  • Page 387

    Suspension 13-13 front fork • separate the inner tube [a] from the outer tube [b] as follows: ○ slide up the spring band [c]. ○ slide up the dust seal [d]. ○ remove the retaining ring [a] from the outer tube. ○ grasp the tubes and stroke the inner tube up and down [a] several times. The shock to for...

  • Page 388

    13-14 suspension front fork • when assembling the new outer tube bushings, washer and new oil seal [a], hold the oil seal against the new one, and tap the oil seal with the fork oil seal driver [b] until it stops. Special tool - fork oil seal driver, 48: 57001-1509 • install the retaining ring to th...

  • Page 389

    Suspension 13-15 front fork adjuster assembly inspection • inspect the adjuster assembly [a] and push rod (left front fork only) [b] for damage. If they are damaged, replace them with new ones. • replace the o-ring [c] on the adjuster assembly with a new one. Base valve assembly inspection • inspect...

  • Page 390

    13-16 suspension front fork • temporarily assemble the inner [a] and outer [b] tubes, and pump them back and forth manually to check for smooth operation. If you feel binding or catching, the inner and outer tubes must be replaced. Warning a straightened inner or outer fork tube may fall in use, pos...

  • Page 391

    Suspension 13-17 rear shock absorber 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. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. Rebound damping adjustment • tu...

  • Page 392

    13-18 suspension rear shock absorber • adjust the high speed compression damping, turn the high speed compression damping adjuster with a wrench. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. Notice do not force the compression damping adjuster beyon...

  • Page 393

    Suspension 13-19 rear shock absorber spring preload adjustment • remove: seat (see seat removal in the frame chapter) side covers (see side cover removal in the frame chapter) muffler body (see muffler body removal in the engine top end chapter) rear frame (see rear frame removal in the frame chapte...

  • Page 394

    13-20 suspension rear shock absorber rear shock absorber spring tension inspection • since the spring becomes shorter as it weakens, check its free length [a] to determine its condition. Shock absorber spring free length standard: 265 mm (10.4 in.) service limit: 260 mm (10.2 in.) if the free length...

  • Page 395

    Suspension 13-21 rear shock absorber • hold the upper end of the rear shock absorber in a vise with soft jaws [a] or a heavy cloth. • using the hook wrenches [b], loosen the locknut [c] and turn the adjusting nut all way up. Special tools - hook wrench r37.5, r42: 57001-1101 hook wrench t=3.2 r37: 5...

  • Page 396

    13-22 suspension rear shock absorber rear shock absorber scrapping warning pressurized nitrogen may explode when heated. The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve. • remove the re...

  • Page 397

    Suspension 13-23 swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) rear flap (see rear flap removal in the frame chap- ter) brake pedal bolt and return spring (see brake pedal removal in the brakes chapter) • remove: bolts [a] and nuts chain guide pl...

  • Page 398

    13-24 suspension swingarm swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • apply a non-permanent locking agent to the chain slipper screws. • install the chain slipper, and tighten the screws. • replace with new ones: swingarm pivot ...

  • Page 399

    Suspension 13-25 swingarm drive chain guide, guide roller, chain slipper wear inspection • visually inspect the drive chain guide [a] and replace it if excessively worn or damaged. • visually inspect the upper and lower chain guide rollers [a] and replace them if excessively worn or damaged. • visua...

  • Page 400

    13-26 suspension tie-rod, rocker arm tie-rod removal • place the jack under the frame so that the rear wheel is raised off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • remove: nut [a] lower chain guide roller [b] • remove: rear tie-rod mounting bolt and nut [a] front ti...

  • Page 401

    Suspension 13-27 tie-rod, rocker arm • remove: rear shock absorber bolt and nut (lower) [a] rocker arm pivot bolt and nut [b] rocker arm [c] rocker arm installation • replace with new ones: rear shock absorber mounting nut (lower) rocker arm pivot nut tie-rod mounting nut • apply plenty of grease to...

  • Page 402

    13-28 suspension tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearings, oil seals and grease seals with new ones. • apply plenty of grease to the oil seals, grease seals and needle bearings. Note ○ install the bearings so that the marked side faces out. ○ inst...

  • Page 403

    Suspension 13-29 tie-rod, rocker arm needle bearing inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings installed in the tie-rod and rocker arm. ○ the needle bearing normally wear very little, and wear is difficult to measure. Instead...

  • Page 404

    13-30 suspension uni-trak maintenance uni-trak linkage inspection • refer to the swingarm and uni-trak linkage inspection in the periodic maintenance chapter. Tie-rod and rocker arm sleeve wear inspection • pull out the sleeves [a] of the tie-rod and rocker arm. • measure the outside diameter of the...

  • Page 405: Steering

    Steering 14-1 14 steering table of contents exploded view........................................................................................................................ 14-2 special tools ..........................................................................................................

  • Page 406

    14-2 steering exploded view.

  • Page 407

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 25 2.5 18 al, 2t 2 front fork clamp bolts (upper) 20 2.0 15 al, l 3 steering stem head nut 98 10.0 72 4 handlebar holder nuts 34 3.5 25 r 5 steering stem nut 4.9 0.50 43 in·lb t 6 brake hose clamp bolt 3....

  • Page 408

    14-4 steering special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 head pipe outer race driver, 54.5: 57001-1077 steering stem ...

  • Page 409

    Steering 14-5 steering steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter. Steering stem, stem bearing removal • remove: number plate [a] (see number plate removal ...

  • Page 410

    14-6 steering steering • remove the upper stem bearing inner race (tapered roller bearing) [a]. • drive out the bearing outer races from the head pipe. ○ remove the outer races pressed into the head pipe, using the head pipe outer race remover [a], and hammer the head pipe outer race remover to driv...

  • Page 411

    Steering 14-7 steering • replace the inner races with new ones. • apply grease to the lower tapered roller bearing [a], and drive it onto the stem with the steering stem bearing driver [b] and adapter [c]. Special tools - steering stem bearing driver: 57001-137 steering stem bearing driver adapter, ...

  • Page 412

    14-8 steering steering • install the removed parts (see appropriate chapters). Torque - brake hose clamp bolt: 3.0 n·m (0.31 kgf·m, 27 in·lb) warning if the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death. Be sure the cables, harnesses and hoses are...

  • Page 413

    Steering 14-9 handlebars handlebar removal • remove: number plate [a] (see number plate removal in the frame chapter) handlebar pad [b] • disconnect: fuel tank breather hose [c] • remove: clutch lever assembly [a] engine stop switch [b] band [c] left handlebar grip [d] • for kx250ze, remove the laun...

  • Page 414

    14-10 steering handlebars handlebar installation • apply adhesive cement to the innermost area of the left handlebar grip and all-around inner surface of the left han- dlebar grip hole entrance and also apply it to the roulette area on the handlebars. • the left handlebar grip must be installed with...

  • Page 415

    Steering 14-11 handlebars • install the handlebars [a] on the steering stem head as follows. ○ the handlebars angle position can be adjusted to suit your preference using the gauge marks [b]. ○ position the handlebars so that the gauge marks is equal positions [c]. Bridge bar [d] • apply 2-stroke oi...

  • Page 417: Frame

    Frame 15-1 15 frame table of contents exploded view........................................................................................................................ 15-2 frame ........................................................................................................................

  • Page 418

    15-2 frame exploded view.

  • Page 419

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 footpeg bracket bolts (upper) 54 5.5 40 l 2 rear frame mounting bolts 34 3.5 25 g: apply grease. L: apply a non-permanent locking agent. R: replacement parts s: follow the specified tightening sequence..

  • Page 420

    15-4 frame frame frame inspection • refer to the frame inspection in the periodic mainte- nance chapter. Rear frame removal • remove: seat (see seat removal) side covers (see side cover removal) muffler body (see muffler body removal in the engine top end chapter) rear fender (see rear fender remova...

  • Page 421

    Frame 15-5 frame engine guards removal • remove the engine guards. Right engine guard [a] left engine guard [b] lower engine guard [c] bolts [d] collars [e] engine guards installation • installation is the reverse of removal. ○ fit the projection [a] of the right engine guard and hole [b] of the fra...

  • Page 422

    15-6 frame seat seat removal • remove the side cover bolt [a] on both sides. • spread [a] the side covers lightly. • take off the seat [b] backward [c]. Seat installation • install the seat. ○ insert the hooks [a] of the seat under the flange collar [b] and brackets [c]. ○ take care not to damage th...

  • Page 423

    Frame 15-7 side covers side cover removal • remove the bolts [a] and take off the side cover [b]. ○ clear the side cover tabs [c] from the air cleaner housing. Side cover installation • stick the pad [a] on the inside of the right side cover. • install the damper [b] securely. • install the side cov...

  • Page 424

    15-8 frame radiator shroud radiator shroud removal • remove: bolts [a] radiator shroud [b] ○ clear the radiator shroud tabs [c] from the air cleaner housing. Radiator shroud installation • install the radiator shrouds. ○ insert the tabs [a] of the radiator shroud into the slots [b] of the air cleane...

  • Page 425

    Frame 15-9 number plate number plate removal • unlock the band [a] of the number plate [b]. • remove the bolt [c]. • clear the projections [d] and remove the number plate. Number plate installation • fit the holes [a] of the number plate and projections [b] of the steering stem base. ○ run the brake...

  • Page 426

    15-10 frame fender front fender removal • remove the bolts [a] and take off the front fender [b]. Front fender installation • temporarily install the front bolts [a] first, and then the rear bolts [b]. • tighten all bolts securely. Rear fender removal/installation • remove the side covers (see side ...

  • Page 427

    Frame 15-11 footpegs footpeg removal • remove: cotter pin [a] washer [b] pivot pin [c] spring [d] footpeg [e] footpeg bracket bolts [f] footpeg bracket [g] footpeg installation • replace the cotter pin with a new one. • apply a non-permanent locking agent to the footpeg bracket bolts [a]. • install ...

  • Page 429: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-2 specifications .......................................................................................

  • Page 430

    16-2 electrical system exploded view.

  • Page 431

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 regulator/rectifier nuts 10 1.02 89 in·lb r 2 spark plug 13 1.3 115 in·lb 3 flywheel nut cap 3.5 0.36 31 in·lb 4 magneto cover bolts 9.8 1.0 87 in·lb 5 timing inspection cap 3.5 0.36 31 in·lb 6 flywheel nut 78.5 8.00 ...

  • Page 432

    16-4 electrical system specifications item standard flywheel magneto magneto output voltage 37 v or more at 4 000 r/min (rpm) stator coil resistance 0.4 ∼ 1.1 Ω at 20°c (68°f) charging system charging voltage (regulator/rectifier output voltage) 14.0 ∼ 14.5 v capacitor internal resistance see text i...

  • Page 433

    Electrical system 16-5 special tools and sealant rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 timing light: 57001-1241 hand tester: 57001-1394 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 needle adapter set: 57001-1457 flywheel puller, m28 × 1.0: 57001-1471 grip: 57001-1591 meas...

  • Page 434

    16-6 electrical system special tools and sealant liquid gasket, tb1211f: 92104-0004.

  • Page 435

    Electrical system 16-7 wiring diagram (kx250zd) this page intentionally left blank..

  • Page 436

    16-8 electrical system wiring diagram (kx250zd).

  • Page 437

    Electrical system 16-9 wiring diagram (kx250zd).

  • Page 438

    16-10 electrical system wiring diagram (kx250ze).

  • Page 439

    Electrical system 16-11 wiring diagram (kx250ze).

  • Page 440

    16-12 electrical system precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the...

  • Page 441

    Electrical system 16-13 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If 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, clea...

  • Page 442

    16-14 electrical system flywheel magneto magneto cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: left radiator shroud (see radiator shroud removal in the frame chapter) shift pedal (see shift pedal removal in the crank- shaft/transmission...

  • Page 443

    Electrical system 16-15 flywheel magneto • hold the flywheel steady with the rotor holder [a], and remove the flywheel nut [b]. Special tools - grip [c]: 57001-1591 rotor holder: 57001-1730 • install the flywheel puller [a] to the flywheel. • install the rotor puller [b] to the flywheel puller. • re...

  • Page 444

    16-16 electrical system flywheel magneto • hold the flywheel steady with the rotor holder, and tighten the flywheel nut. Special tools - grip: 57001-1591 rotor holder: 57001-1730 torque - flywheel nut: 78.5 n·m (8.00 kgf·m, 57.9 ft·lb) • install the magneto cover (see magneto cover installa- tion). ...

  • Page 445

    Electrical system 16-17 flywheel magneto flywheel magneto nspection there are three types of magneto problems: short, open (lead burned out), or loss in flywheel magnetism. A short or open in one of the coil leads will result in either a low output, or no output at all. A loss in flywheel magnetism,...

  • Page 446

    16-18 electrical system flywheel magneto if there is more resistance than shown in the table, or no tester reading (infinity), the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • using the tester, measure the resistanc...

  • Page 447

    Electrical system 16-19 charging system regulator/rectifier removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • open the clamp [a], and free the lead. • slide the dust cover [b]. • disconnect the regulator/rectifier lead connector [c]. • remove: regulator/rectifier...

  • Page 448

    16-20 electrical system charging system • connect the 12 v battery to the main harness (see self -diagnosis procedures in the fuel system (dfi) chapter). • connect a tester [a] to the battery terminals [b]. • start the engine, and note the voltage readings at various engine speeds. But they must be ...

  • Page 449

    Electrical system 16-21 charging system charging system troubleshooting note ○ be sure the prepared battery is fully charged..

  • Page 450

    16-22 electrical system charging system capacitor removal • disconnect the connector [a]. • remove the bolts [b]. • remove the capacitor [c] from the bracket. Capacitor installation • installation is the reverse of removal. ○ run the lead correctly (see cable, wire, and hose rout- ing section in the...

  • Page 451

    Electrical system 16-23 ignition timing ignition timing inspection • remove the timing inspection cap [a]. Special tool - filler cap driver: 57001-1454 • attach the timing light [a] to the ignition coil lead in the manner prescribed by the manufacturer. Special tool - timing light: 57001-1241 • star...

  • Page 452

    16-24 electrical system ignition system safety instructions warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Ignition coil removal • disconnec...

  • Page 453

    Electrical system 16-25 ignition system 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 coil tester for the 3-needle method. • remove the ignition coil (see ignition coil remov...

  • Page 454

    16-26 electrical system ignition system spark plug cleaning and inspection • refer to the spark plug cleaning and inspection in the periodic maintenance chapter. Spark plug gap inspection • refer to the spark plug cleaning and inspection in the periodic maintenance chapter. Ignition coil primary pea...

  • Page 455

    Electrical system 16-27 ignition system ic igniter inspection ○ the ic igniter is built in the ecu. • refer to the following items. Ignition system troubleshooting (see ignition system section) ecu power supply inspection (see ecu power supply inspection in the fuel system (dfi) chapter).

  • Page 456

    16-28 electrical system ignition system.

  • Page 457

    Electrical system 16-29 ignition system crankshaft sensor peak voltage check • disconnect the magneto lead connector (see magneto cover removal). Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained if disconnected. ○ maintain the correct value of co...

  • Page 458

    16-30 electrical system ignition system engine stop switch system check • start the engine. • push the engine stop switch [a], stop the engine. If the engine does not stop, check the engine stop switch for continuity (see engine stop switch inspection). If the engine stop switch is good, check the w...

  • Page 459

    Electrical system 16-31 ignition system • check the wiring for continuity between the terminals of each connector referring the connector circuit. White connector [a] green connector [b] black connector [c] digital meter [d] if a digital meter does not read 0 Ω, the connector is de- fective. Replace...

  • Page 460

    16-32 electrical system switches engine stop switch inspection • using a digital meter, check to see that the connections shown in the table have continuity (about zero ohms). If the switch has an open or short, replace it with a new one. Engine stop switch connection launch control mode button insp...

  • Page 461: Appendix

    Appendix 17-1 17 appendix table of contents cable, wire, and hose routing .............................................................................................. 17-2 troubleshooting guide ...........................................................................................................

  • Page 462

    17-2 appendix cable, wire, and hose routing kx250zd 1. Front brake hose 2. Run the throttle cables inside of the number plate. 3. Throttle cable (accelerator) 4. Throttle cable (decelerator) 5. Clutch cable 6. Run the clutch cable inside of the number plate. 7. Run the front brake hose outside of th...

  • Page 463

    Appendix 17-3 cable, wire, and hose routing kx250ze 1. Front brake hose 2. Run the throttle cables inside of the number plate. 3. Throttle cable (accelerator) 4. Throttle cable (decelerator) 5. Clutch cable 6. Run the clutch cable inside of the number plate. 7. Run the front brake hose outside of th...

  • Page 464

    17-4 appendix cable, wire, and hose routing 1. Fi warning indicator light harness connector (kx250zd) launch control mode button lead connector (kx250ze) 2. Clutch cable 3. Engine stop switch lead 4. Main harness 5. Run the clutch cable outside of the main harness. 6. Clamps (firmly twist the clamp ...

  • Page 465

    Appendix 17-5 cable, wire, and hose routing 1. Engine stop switch lead 2. Clamp (hold the main harness and engine stop switch lead on the main harness at the white taped position.) 3. Position the engine stop switch lead connector behind the clamp and between the main harness and frame. 4. Run the c...

  • Page 466

    17-6 appendix cable, wire, and hose routing 1. Clamp (turn the lock position to upward.) 2. Clamp (turn the lock position to upward.) 3. Run the main harness and option lead over the capacitor lead. 4. Run the regulator/rectifier lead as shown. 5. Run the regulator/rectifier lead on the top position...

  • Page 467

    Appendix 17-7 cable, wire, and hose routing this page intentionally left blank..

  • Page 468

    17-8 appendix cable, wire, and hose routing.

  • Page 469

    Appendix 17-9 cable, wire, and hose routing 1. Breather hose 2. Downstream lead 3. Throttle sensor lead 4. Install the upstream injector connector boot so that notch side faces inside. 5. Run the downstream lead and throttle sensor lead over the throttle body assy rear side. 6. Fuel hose 7. Check th...

  • Page 470

    17-10 appendix cable, wire, and hose routing 1. Clamp (twist the clamp on the magneto lead and gear position switch lead at the gray taped position.) 2. Clamp (twist the clamp on the magneto lead and gear position switch lead.) 3. Run the gear position switch lead inside of the gasket. 4. Do not pin...

  • Page 471

    Appendix 17-11 cable, wire, and hose routing 1. Viewed rear 2. Radiator overflow hose 3. Clamps 4. Joint hose (turn the blue paint to upside.) 5. Clamps (turn the screw head to outside.) 6. Right radiator 7. Water pipe 8. Run the radiator overflow hose in the front of the water hose and between the ...

  • Page 472

    17-12 appendix cable, wire, and hose routing 1. Install the mesh protector side of the breather hose to the engine. 2. Clamp (turn the claw to the exhaust pipe side.) 3. Clamp (run the breather hose into the clamp.) 4. Breather hose 5. Align the green paint to the stopper. 6. Stoppers 7. Align the r...

  • Page 473

    Appendix 17-13 cable, wire, and hose routing 1. Touch the front brake hose fitting to the stopper. 2. Brake hose 3. Clamp 4. Viewed a 5. Clamps.

  • Page 474

    17-14 appendix cable, wire, and hose routing 1. Brake hose 2. Clamps 3. Touch the rear brake hose fitting to the stopper. 4. Cotter pin 5. Viewed a.

  • Page 475

    Appendix 17-15 troubleshooting guide note ○ refer to the fuel system (dfi) chapter for most of dfi trouble shooting guide. ○ 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 com...

  • Page 476

    17-16 appendix troubleshooting guide spark plug cap shorted or not in good con- tact spark plug incorrect heat value ecu trouble crankshaft sensor trouble flywheel damage ignition coil trouble wiring connector not in good contact fuel/air mixture incorrect: air cleaner clogged, poorly sealed, or mis...

  • Page 477

    Appendix 17-17 troubleshooting guide gear seized gear positioning lever operation trouble shift drum broken jumps out of gear: shift fork ear worn, bent gear groove worn gear dogs and/or dog holes worn shift drum groove worn gear positioning lever spring weak or bro- ken shift fork guide pin worn dr...

  • Page 478

    17-18 appendix troubleshooting guide steering stem bearing lubrication inade- quate steering stem bent tire air pressure too low handlebars shakes or excessively vibrates: tire worn swingarm pivot bearings worn rim warped, or not balanced spokes loose wheel bearing worn handlebar clamp bolt loose st...

  • Page 479

    Model application year model beginning frame no. 2013 kx250zd jkakxmzc □ da000001 jkakx250zza000001 2014 kx250ze jkakxmzc □ ea013001 jkakx250zza013001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1459-02 printed in japan.