2008 Kawasaki KX250T8F Service Repair Manual

MODEL APPLICATION Year

Model

2006

KX250T6F

2007

KX250T7F

2008

KX250T8F

Beginning Frame No. JKAKXMTC□6A000001 or JKAKX250TTA000001 JKAKXMTC□7A011001 or JKAKX250TTA011001 JKAKXMTC□8A026001 or JKAKX250TTA026001

□:This digit in the frame number changes from one machine to another.

Part No.99924-1354-04

Printed in Japan

KX250F

Motorcycle Service Manual

Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 j

Fuel System

3 j

Cooling System

4 j

Engine Top End

5 j

Engine Right Side

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

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 Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

Š 2005 Kawasaki Heavy Industries, Ltd.

Fourth Edition (1) : May 22, 2007 (K)

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h kg kgf L

ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) (mass) hour(s) (mass) (force) liter(s)

lb m min N Pa PS psi r r/min, rpm TDC TIR V W Ω

pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop.

However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual.

Be alert for problems and non-scheduled maintenance.

Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual carefully. Don’t take shortcuts.

Remember to keep complete records of maintenance and repair with dates and any new parts installed.

• • •

• •

How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want stick coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Stick Coil section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance practices.

WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation.

a procedural step or work to be • Indicates done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

1

Table of Contents Before Servicing .....................................................................................................................

Model Identification.................................................................................................................

General Specifications............................................................................................................

Unit Conversion Table ............................................................................................................

1-2 1-7 1-8 1-10

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

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.

Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

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 tightening with torque wrench.

Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

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 pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

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. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

GENERAL INFORMATION 1-7 Model Identification KX250T6F Left Side View

KX250T6F Right Side View

1-8 GENERAL INFORMATION General Specifications KX250T6F ∼ T8F

Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil: Grade Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio

2 160 mm (85.04 in.)

820 mm (32.3 in.)

1 270 mm (50 in.)

1 469 mm (57.83 in.)

372 mm (14.6 in.) (KX250T6F), 335 mm (13.2 in.) (KX250T7F ∼) 960 mm (37.8 in.) (KX250T6F), 955 mm (37.6 in.) (KX250T7F ∼) 92.5 kg (204 lb) 49.9 kg (110 lb) 52.6 kg (116 lb) 7.2 L (1.9 US gal) – 4-stroke, single cylinder, DOHC 4 valve Liquid-cooled 77.0 × 53.6 mm (3.03 × 2.11 in.)

249 cm³ (15.2 cu in.)

13.5 : 1 Carburetor, KEIHIN FCR37 Primary kick Digital AC-CDI BTDC 8° @2 000 r/min (rpm) NGK CR8E

BTDC 41° ABDC 71° 292° BBDC 69° ATDC 49° 298° Forced lubrication (semi-dry sump) API SG, SH, SJ or SL with JASO MA SAE 10W-40 1.5 L (1.6 USqt)

Gear 3.350 (67/20)

GENERAL INFORMATION 1-9 General Specifications Items Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th Final Drive System: Type Reduction Ratio Overall Drive Ratio Frame Type Steering Angle Caster (Rake Angle) Trail Front Wheel: Tire Size Tire Make/Type

Rim Size Rear Wheel: Tire Size Tire Make/Type

Rim Size Front Suspension: Type Wheel Travel Rear Suspension: Type Wheel Travel Brake Type: Front and Rear Effective Disc Diameter: Front (effect. dia.)

Rear (effect. dia.)

KX250T6F ∼ T8F Wet, multi disc, Manual 5-speed, constant mesh, return shift 2.142 (30/14) 1.785 (25/14) 1.444 (26/18) 1.200 (24/20) 1.052 (20/19) (KX250T6F), 1.045 (23/22) (KX250T7F ∼) Chain drive 3.692 (48/13) 13.020 @Top gear (KX250T6F), 12.931 @Top gear (KX250T7F ∼) semi-double cradle 42° to either side 27.7° 119 mm (4.69 in.)

80/100-21 51M BRIDGESTONE M401, Tube type (KX250T6F ∼ T7F) BRIDGESTONE M403, Tube type (KX250T8F) BRIDGESTONE M201 (EUR), Tube type 21 × 1.60 100/90-19 57M BRIDGESTONE M402, Tube type (KX250T6F ∼ T7F) BRIDGESTONE M404, Tube type (KX250T8F) BRIDGESTONE M202 (EUR), Tube type 19 × 1.85 Telescopic fork (up side down) 315 mm (12.4 in.)

Swingarm (New Uni-trak) 310 mm (12.2 in.)

Single disc 225 mm (8.86 in.)

215 mm (8.46 in.)

EUR: Europe Model Specifications are subject to change without notice, and may not apply to every country.

1-10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Symbol M k c m µ

Units of Length:

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

km m mm

× × ×

0.6214 3.281 0.03937

= = =

mile ft in

= = = = = =

kgf·m ft·lb in·lb N·m ft·lb in·lb

= = = = = =

kgf/cm² psi cm Hg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

Units of Pressure: Units of Volume: L L L L L L mL mL mL

× × × × × × × × ×

0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

= = = = = = = = =

gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

Units of Force: N N kgf kgf

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature:

kPa kPa kPa kgf/cm² kgf/cm² cm Hg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

×

0.6214

Units of Power: = = = =

kgf lb N lb

kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance 2

Table of Contents Periodic Maintenance Chart ...................................................................................................

Torque and Locking Agent......................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Periodic Maintenance Procedures..........................................................................................

Fuel System.........................................................................................................................

Fuel Hose and Connection Inspection ..............................................................................

Throttle Grip (Throttle Cable) Free Play Inspection ..........................................................

Throttle Grip (Throttle Cable) Free Play Adjustment.........................................................

Hot Starter Lever (Hot Starter Cable) Free Play Inspection..............................................

Idle Speed Inspection (Carburetor Inspection) .................................................................

Idle Speed Adjustment (Carburetor Adjustment) ..............................................................

Air Cleaner Element Cleaning and Inspection ..................................................................

Fuel System Clean............................................................................................................

Cooling System....................................................................................................................

Coolant Level Inspection...................................................................................................

Coolant Deterioration Inspection.......................................................................................

Water Hoses and Connections Inspection ........................................................................

Engine Top End ...................................................................................................................

Valve Clearance Inspection ..............................................................................................

Valve Clearance Adjustment.............................................................................................

Cylinder Head Warp Inspection ........................................................................................

Cylinder Wear Inspection..................................................................................................

Piston/Cylinder Clearance Inspection ...............................................................................

Piston, Piston Ring and Piston Pin Replacement .............................................................

Exhaust System Inspection...............................................................................................

Muffler Baffle Change .......................................................................................................

Engine Right Side ................................................................................................................

Clutch Inspection ..............................................................................................................

Clutch Plates Inspection ...................................................................................................

Engine Lubrication System ..................................................................................................

Engine Oil Change............................................................................................................

Oil Filter Change ...............................................................................................................

Breather Hose Inspection .................................................................................................

Crankshaft/Transmission .....................................................................................................

Crankshaft Inspection .......................................................................................................

Wheel/Tires..........................................................................................................................

Air Pressure Inspection/Adjustment..................................................................................

Tires Inspection.................................................................................................................

Spoke Tightness Inspection ..............................................................................................

Rim Runout Inspection......................................................................................................

Wheel Bearing Inspection .................................................................................................

Final Drive............................................................................................................................

Drive Chain Wear Inspection ............................................................................................

Drive Chain Slack Inspection ............................................................................................

Drive Chain Slack Adjustment ..........................................................................................

2-3 2-5 2-10 2-13 2-14 2-14 2-14 2-14 2-14 2-15 2-15 2-16 2-17 2-19 2-20 2-20 2-21 2-21 2-22 2-22 2-22 2-24 2-25 2-25 2-25 2-26 2-26 2-27 2-27 2-28 2-29 2-29 2-30 2-31 2-31 2-31 2-32 2-32 2-32 2-33 2-33 2-34 2-34 2-34 2-35 2-35

2-2 PERIODIC MAINTENANCE Drive Chain Lubrication.....................................................................................................

Sprocket Wear Inspection.................................................................................................

Rear Sprocket Warp (Runout) Inspection .........................................................................

Brakes..................................................................................................................................

Brake Lever and Pedal Adjustment ..................................................................................

Brake Fluid Level Inspection.............................................................................................

Brake Fluid Change ..........................................................................................................

Brake Pad Wear Inspection ..............................................................................................

Brake Master Cylinder Cup and Dust Cover Replacement...............................................

Caliper Fluid Seal and Dust Seal Replacement................................................................

Brake Hoses and Connections Inspection ........................................................................

Brake Hose Replacement .................................................................................................

Suspension ..........................................................................................................................

Front Fork Inspection ........................................................................................................

Front Fork Oil Change (each fork leg) ..............................................................................

Rear Shock Absorber Oil Change.....................................................................................

Swingarm and Uni-Trak Linkage Inspection .....................................................................

Swingarm and Uni-Track Linkage Pivot Lubrication .........................................................

Steering ...............................................................................................................................

Steering Inspection ...........................................................................................................

Steering Adjustment .........................................................................................................

Steering Stem Bearing Lubrication ...................................................................................

Frame ..................................................................................................................................

Frame Inspection ..............................................................................................................

Electrical System .................................................................................................................

Spark Plug Cleaning and Inspection.................................................................................

Spark Plug Replacement ..................................................................................................

General Lubrication and Cable Inspection...........................................................................

Lubrication ........................................................................................................................

Nut, Bolt, and Fastener Tightness Inspection......................................................................

Tightness Inspection .........................................................................................................

2-36 2-37 2-37 2-37 2-37 2-39 2-40 2-42 2-42 2-43 2-46 2-46 2-48 2-48 2-48 2-58 2-67 2-68 2-68 2-68 2-68 2-70 2-71 2-71 2-71 2-71 2-72 2-72 2-72 2-73 2-73

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 Spark plug - clean, inspect † Spark plug - replace Clutch - inspect Clutch plates - inspect † Throttle cable - inspect and adjust Air cleaner element - clean Air cleaner element - replace Carburetor - inspect and adjust Engine Oil - change E N G I N E

Each Every 3 Every 6 Every 12 See race or races or races or races or Page 2.5 hr 7.5 hr 15 hr 30 hr

• • • • •

2-70

•

2-71 2-26 2-27 2-13 2-16

If damaged

•

2-14

• • •

Piston and piston ring - replace Cylinder head, cylinder - inspect Piston pin - replace

•

Valve clearance - inspect † Hot starter cable - inspect Oil filter - replace Exhaust system - inspect† Muffler baffle- change Kick pedal and shift pedal - clean Engine sprocket - inspect † Coolant level - inspect Water hoses and connections - inspect † Crankshaft - inspect Breather hose - inspect Brake - adjust † Brake pad wear - inspect † Brake fluid level - inspect †

Brake fluid - change C Brake master cylinder cup and dust cover - replace H Brake caliper fluid seal and dust seal - replace A Brake hoses and pipe - replace S Brake hoses, connections - inspect † S I Spoke tightness and rim runout - inspect † S Wheel bearing - inspect † Frame - inspect Drive chain wear - inspect † Drive chain - inspect and adjust Drive chain - lubricate

• • • • • • • • • •

• • • • • • •

2-16

• •

2-28 2-24 2-23

•

2-24 2-21 2-14 2-29 2-25 2-25 – 2-36 2-19 2-20

•

2-30 2-29 2-36 2-41 2-38

Every Every Every Every

2 2 2 4

years years years years

2-39 2-41 2-42 2-45 2-45 2-31 2-32 2-70 2-33 2-34 2-35

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY OPERATION Wheels/tires - inspect Rear sprocket - inspect † Front fork - inspect and clean Front fork oil - change

Each Every 3 Every 6 Every 12 See race or races or races or races or Page 2.5 hr 7.5 hr 15 hr 30 hr

• • •

2-30 2-36 2-47

• •

Rear shock absorber oil - change Cable - inspect Fuel hose - replace Fuel hose, connections - inspect † Fuel system - clean Steering play - inspect † Steering stem bearing - lubricate

• • •

Swingarm and Uni-Trak linkage pivots - lubricate Swingarm and Uni-Trak linkage pivots - inspect † Nuts, bolts, fasteners - inspect † General lubrication - perform †: Replace, add, adjust, clean or torque if necessary.

• •

Every 4 years

2-47 2-57 2-71 2-13 2-13

• • •

2-18 2-67

•

2-69 2-67 2-66 2-72 2-71

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 toque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.

When checking the tightening toque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten to specified torque.

Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand Threads MO: Apply molybdenum disulfide oil (mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 : 1).

S: Tighten the fasteners following the specified sequence.

St: Stake the fasteners to prevent loosening.

Basic Torque for General Fasteners Threads dia. (mm) 5 6 8 10 12 14 16 18 20

Torque kgf·m 0.35 ∼ 0.50 0.60 ∼ 0.80 1.4 ∼ 1.9 2.6 ∼ 3.5 4.5 ∼ 6.2 7.4 ∼ 10.0 11.5 ∼ 16.0 17.0 ∼ 23.0 23 ∼ 33

N·m 3.4 ∼ 4.9 5.9 ∼ 7.8 14 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325

Fastener Fuel System Air Cleaner Element Wing Bolt Throttle Pulley Cover Bolt Throttle Cable Bolts Hot Starter Plunger Cap Bolt Air Cleaner Duct Bolt and Nuts Rear Frame Mounting Bolts Air Cleaner Housing Bolts Air Cleaner Duct Clamp Screws Carburetor Holder Clamp Screws Fuel Tap Plate Mounting Screws Cooling System Right Engine Cover Bolt Water Pipe Bolt Water Pump Cover Bolts Water Pump Cover Bolts (with washer) Water Pump Impeller Bolt

N·m

Torque kgf·m

ft·lb 30 ∼ 43 in·lb 52 ∼ 69 in·lb 10.0 ∼ 13.5 19.0 ∼ 25 33 ∼ 45 54 ∼ 72 83 ∼ 115 125 ∼ 165 165 ∼ 240

ft·lb

– 3.4 7.0 1.0 3.0 34 9.8 3.0 2.0 0.8

– 0.35 0.7 0.1 0.3 3.5 1.0 0.3 0.2 0.08

– 30 in·lb 61 in·lb 10 in·lb 27 in·lb 25 87 in·lb 27 in·lb 17 in·lb 7 in·lb

9.8 9.8 9.8 9.8 7.0

1.0 1.0 1.0 1.0 0.7

87 87 87 87 61

in·lb in·lb in·lb in·lb in·lb

Remarks

Hand Tighten

L (1) L (1)

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Water Hose Clamp Screws Radiator Screen Bolts Coolant Drain Plug Radiator Mounting Bolts Radiator Shroud Bolts Engine Top End Auto-Decompressor Bolt Decompressor Plug Plate Bolt Cylinder Head Cover Bolts Cylinder Head Bolts: M10 M6 Camshaft Cap Bolts Carburetor Holder Clamp Screws Plug Lower Camshaft Chain Guide Bolt Rear Camshaft Chain Guide Bolt Exhaust Pipe Stud Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Tensioner Cap Bolt Cylinder Bolt M6 Exhaust Pipe Cover Screws Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Pipe Mounting Bolts Engine Right Side Primary Gear Nut Shift Drum Cam Bolt Clutch Spring Bolts Clutch Hub Nut Gear Set Lever Nut Gear Set Lever Pivot Stud Ratchet Plate Mounting Bolt Ratchet Plate Mounting Screw (KX250T6F) Ratchet Plate Mounting Bolt Kick Ratchet Guide Bolt Kick Pedal Mounting Bolt Shift Pedal Bolt Oil Filler Plug Clutch Cover Bolts (with right engine cover)

N·m 1.5 9.8 7.0 9.8 9.8

Torque kgf·m 0.15 1.0 0.7 1.0 1.0

ft·lb 13 in·lb 87 in·lb 61 in·lb 87 in·lb 87 in·lb

Remarks

12 9.8 9.8

1.2 1.0 1.0

104 in·lb 87 in·lb 87 in·lb

49 12 9.8 2.0 20 9.8 15 –

5.0 1.2 1.0 0.2 2.0 1.0 1.5 –

36 104 in·lb 87 in·lb 17 in·lb 14 87 in·lb 11 –

9.8 20 12 12 21 21 12

1.0 2.0 1.2 1.2 2.1 2.1 1.2

87 in·lb 14.5 104 in·lb 104 in·lb 15 15 104 in·lb

98 24 9.8 98 8.8 –

10 2.4 1.0 10 0.9 –

72 17 87 in·lb 72 78 in·lb –

9.8

1.0

87 in·lb

L (Planted Side) L

6.4

0.65

56 in·lb

L

15 8.8 25 9.8 5.0 9.8

1.5 0.9 2.5 1.0 0.51 1.0

11 78 in·lb 18 87 in·lb 44 in·lb 87 in·lb

L L L

S, MO S S L

L (Planted side)

S S S L Lh L St

L (2)

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Clutch Cover Bolts Right Engine Cover Bolts Engine Lubrication System Engine Oil Drain Bolt M10 (for transmission room oil sump) Engine Oil Drain Bolt M6 (for crank room oil sump) Oil Filter Cap Bolts Oil Pump Mounting Bolts Water Pump Cover Bolts Water Pump Cover Bolt (with washer) Right Engine Cover Bolts Breather Fitting Oil Pump Idle Gear Shaft Screws Engine Removal/Installation Engine Mounting Nuts Engine Bracket Nuts Swingarm Pivot Shaft Nut Crankshaft/Transmission Breather Fitting Reed Valve Screws Piston Oil Nozzle Crankcase Bolts Engine Oil Drain Bolt (for crank room oil sump) (for transmission room oil sump) Output Shaft Bearing Retaining Screw (KX250T6F) Output Shaft Bearing Retaining Bolts Drive Shaft Bearing Retaining Screw (KX250T6F) Drive Shaft Bearing Retaining Bolt Shift Drum Bearing Retaining Bolts Gear Set Lever Nut Shift Drum Cam Bolt Neutral Switch Wheels/Tires Front Axle Front Axle Clamp Bolts Rear Axle Nut Spoke Nipple

N·m 9.8 9.8

Torque kgf·m 1.0 1.0

ft·lb 87 in·lb 87 in·lb

Remarks

20

2.0

14.5

7.0 9.8 7.0 9.8 9.8 9.8 15 6.4

0.7 1.0 0.7 1.0 1.0 1.0 1.5 0.65

49 29 98

5.0 3.0 10

33 22 72

15 7.0 2.9 9.8

1.5 0.7 0.29 1.0

11 61 in·lb 26 in·lb 87 in·lb

S

7.0 20 6.4

0.7 2.0 0.65

61 in·lb 14.5 56 in·lb

L

12 6.4

1.2 0.65

104 56 in·lb

L L

9.8 9.8 8.8 24 12

1.0 1.0 0.9 2.4 1.2

87 87 in·lb 78 in·lb 17 104 in·lb

L L

79 20 108 Not less than 2.2

8.0 2.0 11 Not less than 0.22

58 14.5 80 Not less than 19 in·lb

61 87 61 87 87 87

in·lb in·lb in·lb in·lb in·lb in·lb 11 56 in·lb

L L (1) L (1) L L

L

L

AL

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Final Drive Rear Sprocket Nuts Engine Sprocket Cover Bolts Brakes Brake Lever Pivot Bolt Locknut Brake Reservoir Cap Screws Brake Lever Pivot Bolt Caliper Mounting Bolts (Front) Brake Hose Banjo Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Brake Reservoir Cap Bolts Brake Disc Mounting Bolts: (Front) (Rear) Caliper Bleed Valves (Front, Rear) Rear Caliper Holder Shaft Brake Pad Bolts Rear Brake Pad Bolt Plug Brake Pedal Mounting Bolt Suspension Front Fork Cylinder Unit Front Fork Clamp Bolts (Upper) (Lower) Front Fork Adjuster Assembly Front Fork Base Valve Assembly Adjuster Assembly Locknut Pressure Relief Screw Swingarm Pivot Shaft Nut Rear Shock Absorber Mounting Nuts: (Upper) (Lower) Rear Shock Absorber Spring Locknut Piston Rod Locknut Gas Reservoir Damping Adjuster Assembly Tie-Rod Mounting Nut (Front, Rear) (KX250T6F) Tie-Rod Mounting Nut (Front, Rear) Rocker Arm Pivot Nut (KX250T6F) Rocker Arm Pivot Nut

N·m

Torque kgf·m

ft·lb

34 9.8

3.5 1.0

25 87 in·lb

5.9 1.5 5.9 25 25 8.8 9.8 17 1.5

0.6 0.15 0.6 2.5 2.5 0.9 1.0 1.7 0.15

52 in·lb 13 in·lb 52 in·lb 18 18 78 in·lb 87 in·lb 12.5 13 in·lb

9.8 23 7.8 27 17 2.5 25

1.0 2.3 0.8 2.8 1.7 0.25 2.5

87 in·lb 16.5 69 in·lb 20 12.5 22 in·lb 18

34

3.5

25

20 20 69 29 22 1.3 98

2.0 2.0 7.0 3.0 2.2 0.13 10

14.5 14.5 51 22 16 11 in·lb 72

39 34 45 37 29

4.0 3.5 4.6 3.8 3.0

29 25 33 27 21

83

8.5

61

59 83 59

6.0 8.5 6.0

44 61 44

Remarks

S

L L

L, G

L, AL AL L

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Steering Steering Stem Head Nut Steering Stem Locknut Handlebar Clamp Bolts Frame Footpeg Bracket Bolts (Upper) Rear Frame Mounting Bolts Electrical System Neutral Switch Neutral Switch Lead Terminal Screw Flywheel Nut Flywheel Plug Timing Inspection Plug Stator Bolts Crankshaft Sensor Bolts Spark Plug C.D.I. Unit Bolts Magneto Cover Bolts L: 30 L: 35

N·m

Torque kgf·m

ft·lb

98 4.9 25

10 0.5 2.5

72 43 in·lb 18

54 34

5.5 3.5

40 25

12 1.3 49 5.0 4.0 7.0 7.0 13 9.8

1.2 0.13 5.0 0.5 0.4 0.7 0.7 1.3 1.0

104 in·lb 12 in·lb 36 44 in·lb 35 in·lb 61 in·lb 61 in·lb 113 in·lb 87 in·lb

9.8 9.8

1.0 1.0

87 in·lb 87 in·lb

Remarks

S L

L

2-10 PERIODIC MAINTENANCE Specifications Item Fuel System Throttle Grip Free Play Hot Starter Lever Free Play Idle Speed Air Cleaner Element Oil Cooling System Coolant: Type (recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Inlet Cylinder Head Warp

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

2 000 r/min (rpm) High quality foam air filter oil

– – – –

– – – –

– – – –

Permanent type antifreeze Green Soft water 50% and coolant 50% -35°C (-31°F) 1.10 L (1.16 US qt)

– – – – –

– – – – –

– – – – –

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

–––

Cylinder Inside Diameter (see text) 77.000 ∼ 77.012 mm (3.0315 ∼ 3.0320 in.)

Piston/cylinder Clearance 0.030 ∼ 0.057 mm (0.0012 ∼ 0.0022 in.)

Engine Right Side Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.)

Friction Plate Thickness 2.7 ∼ 2.9 mm (0.106 ∼ 0.114 in.)

Steel Plate Thickness 1.5 ∼ 1.7 mm (0.059 ∼ 0.067 in.)

Friction Plate Warp 0.15 mm (0.0059 in.) or less Steel Plate Warp 0.15 mm (0.0059 in.) or less Engine Lubrication System Engine Oil: Grade Castrol “R4 superbike” 5W-40 (KX250T6F ∼ T7F), Castrol “POWER1 R4 Racing” 5W-40 (KX250T8F) or API SG, SH, SJ or SL with JASO MA Viscosity SAE 10W-30, 10W-40, or 10W-50 Capacity 1.5 L (0.74 US qt) Crankshaft/Transmission 0.25 ∼ 0.35 mm Connecting Rod Big End Side Clearance (0.0098 ∼ 0.0138 in.)

– – – – – – 0.05 mm (0.0020 in.)

77.06 mm (3.0339 in.)

– – –

– – – 2.6 mm (0.102 in.)

1.4 mm (0.055 in.)

0.3 mm (0.012 in.)

0.3 mm (0.012 in.)

– – – – – – – – – – – – 0.55 mm (0.0217 in.)

PERIODIC MAINTENANCE 2-11 Specifications Item Wheels/Tires Rim Runout (with tire installed): Axial Radial Front and Rear Tires Air Pressure Standard Tire: Front: Size Make Type Rear: Size Make Type Final Drive Drive Chain Slack Drive Chain 20 Link Length Rear Sprocket Warp (Runout) Brakes Brake Lever Free Play Brake Fluid: Type: Front Rear Brake pad lining thickness: Front Rear Suspension Fork Oil: Oil Viscosity

Standard

TIR 1.0 mm (0.04 in.) or less TIR 1.0 mm (0.04 in.) or less 100 kPa (1.0 kgf/cm², 14 psi)

Service Limit

TIR 2 (0.08 TIR 2 (0.08 – –

mm in.) mm in.)

–

80/100-21 51M BRIDESTONE M401, Tube (KX250T6F ∼ T7F) M403, Tube (KX250T8F) (EUR) M201, Tube

– – – – – –

100/90-19 57M BRIDESTONE M402, Tube (KX250T6F ∼ T7F) M404, Tube (KX250T8F) (EUR) M202, Tube

– – – – – –

52 ∼ 58 mm (2.05 ∼ 2.28 in.)

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

TIR 0.4 mm (0.016 in.) or less

– – – – – –

– – – – – – – – – 323 mm (12.72 in.)

TIR 0.5 mm (0.020 in.)

(to suit rider)

– – –

DOT3 or DOT4 DOT4

– – – – – –

4.0 mm (0.157 in.)

6.4 mm (0.252 in.)

SHOWA SS-05 or equivalanet

1 mm (0.04 in.)

1 mm (0.04 in.)

– – –

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