Water Right IMP-1354 Wartungshandbuch

KX250FMotorcycleService Manual

1-2 GENERAL INFORMATIONBefore ServicingBefore starting to perform an inspection service or carry out a disassembly and reassembly opera-tion on a moto

3-8 FUEL SYSTEMThrottle Grip and CableIf the throttle grip has excessive free play due to cablestretch or misadjustment, there will be a delay in thro

FUEL SYSTEM 3-9Throttle Grip and Cable•Unscrew the bolt [A].•Remove the throttle pulley cover [B].•Loosen the mounting bolts [A].•Remove the cables [B

3-10 FUEL SYSTEMThrottle Grip and CableThrottle Cable Lubrication•Whenever the throttle cable is removed or in accordancewith the Periodic Maintenance

FUEL SYSTEM 3-11Throttle Grip and Cable•Remove:Fuel Tank (see Fuel Tank Removal)•Pull out the cable [B] from the clamps [A].Hot Start Cable Installati

3-12 FUEL SYSTEMCarburetorSince the carburetor regulates and mixes the fuel and airgoing to the engine, there are two general types of carbure-tor tro

FUEL SYSTEM 3-13Carburetor•Read the fuel level in the gauge and compare it to thespecification.Service Fuel Level (below the bottom edge of the carb.b

3-14 FUEL SYSTEMCarburetorNOTE○Float height [A] is the distance from the float bowl mat-ing surface [B] of the carburetor body (with the gasketremoved

FUEL SYSTEM 3-15Carburetor•Remove:SeatSide CoverSilencerRear Frame Bolts [B]•Loosen the clamp screws [A] of the air cleaner duct.•Pull out the rear fr

3-16 FUEL SYSTEMCarburetor•Loosen the mounting bolts [A].•Pull out the end of the throttle cables [B].•Free the tips [C].•Pull out the air vent tubes

FUEL SYSTEM 3-17Carburetor•Fit the claw [A] of the clamp onto the groove [B] of theinlet duct.•Insert the duct end between the frame and shock ab-sorb

GENERAL INFORMATION 1-3Before ServicingStorage of Removed PartsAfter all the parts including subassembly parts have beencleaned, store the parts in a

3-18 FUEL SYSTEMCarburetor•Unscrew the screw [A].•Pull out the fuel hose fitting [B].•Unscrew the carburetor cap bolts [A].•Remove the carburetor cap

FUEL SYSTEM 3-19Carburetor•Remove the throttle pulley shaft [ A] with the spring [B],steel washer [C], plastic washer [D] and throttle valve link[E].○

3-20 FUEL SYSTEMCarburetor•Unscrew the screws [A].•Remove the acceleration pump cover [B] from the carbu-retor.•Remove the spring [A], diaphragm [B],

FUEL SYSTEM 3-21Carburetor•Unscrew the leak jet [A].•Remove:E-clip [A]Washer [B]•Pull out the acceleration pump lever assembly [C] as aset.•Remove the

3-22 FUEL SYSTEMCarburetorCarburetor CleaningWARNINGClean the carburetor in a well-ventilated area, andtake care that there is no spark or flame anywh

FUEL SYSTEM 3-23Carburetor•Remove the carburetor.•Before disassembling the carburetor, check the fuel level(see Fuel Level Inspection).If the fuel lev

3-24 FUEL SYSTEMCarburetor•Check the jet needle for wear.A worn jet needle should be replaced.•For the throttle sensor inspection, see Throttle Sensor

FUEL SYSTEM 3-25Carburetor•Install:Washer [A]E-clip [B]•Apply thin coat silicone grease to the shaft.•Fit the hook [A] of the return spring onto the s

3-26 FUEL SYSTEMCarburetor•Install the push rod [A] into the push rod holder [B].•Apply a grease to the O-ring [A].•Fit the stopper [B] of the throttl

FUEL SYSTEM 3-27Carburetor•Install:Starter Jet [A]Pilot Jet [B]Baffle Plate [C]Needle Jet [D]Main Jet [E]•Replace the O-ring with new one.•Install:Pil

1-4 GENERAL INFORMATIONBefore ServicingTightening TorqueIncorrect torque applied to a bolt, nut, or screw maylead to serious damage. Tighten fasteners

3-28 FUEL SYSTEMCarburetor•Replace the O-rings with new ones.•Fit the O-rings [A].•Install:Diaphragm [B]Spring [C]Acceleration Pump Cover○Install the

FUEL SYSTEM 3-29Carburetor•If turn the adjusting screw of the acceleration pump, followthe procedure below.○Adjust the acceleration pump timing.○Selec

3-30 FUEL SYSTEMAir CleanerAir Cleaner Hou s ing Removal•Remove:Side Covers (see Side Cover Removal in the Framechapter)Seat (see Seat Removal in the

FUEL SYSTEM 3-31Air CleanerElement Installation•When installing the element, coat the lip of the elementwith a thick layer of all purpose grease [A] t

3-32 FUEL SYSTEMFuel TankFuel Tank RemovalWARNINGGasoline is extremely flammable and can be ex-plosive under certain conditions. Always stop theengine

FUEL SYSTEM 3-33Fuel Tank•Install the rubber dampers [A] position as shown in thefigure.○Apply adhesive cement to the contact portion of thedamper.•Be

COOLING SYSTEM 4-14Cooling SystemTable of ContentsExploded View...

4-2 COOLING SYSTEMExploded View

COOLING SYSTEM 4-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Water Pump Cover Bolts 9.8 1.0 87 in·lb L(1)2 Water Pump Cover Bolts (with wa

GENERAL INFORMATION 1-5Before ServicingBall Bearing and Needle BearingDo not remove pressed ball or needle unless removal isabsolutely necessary. Repl

4-4 COOLING SYSTEMSpecificationsItem Service LimitCoolantType Permanent type antifreeze for aluminum engines and radiatorsColor GreenMixed Ratio Soft

COOLING SYSTEM 4-5Special ToolBearing Driver Set:57001-1129

4-6 COOLING SYSTEMCoolantCheck the coolant level each day before riding the motor-cycle, and replenish coolant if the level is low. Change thecoolant

COOLING SYSTEM 4-7Coolant•Place a container under the c oolant drain plug [A], anddrain the coolant from the radiator and engine by remov-ing the drai

4-8 COOLING SYSTEMCoolantAir BleedingBefore putting the motorcycle into operation, any airtrapped in the cooling system must be removed as follows.•St

COOLING SYSTEM 4-9CoolantCooling System FlushingOver a period of time, the cooling system accumulatesrust, scale, and lime in the water jacket and rad

4-10 COOLING SYSTEMWater PumpWater Pump Cover Removal•Drain the engine oil from the water pump cover.○Unscrew the bolts [A] and remove the oil filter

COOLING SYSTEM 4-11Water Pump•Apply grease to the water pipe O-ring [A].•Insert the water pipe [B] straightly into the hole of the wa-ter pump cover.•

4-12 COOLING SYSTEMWater Pump•Check the drainage outlet passage [A] at the bottom ofthe right engine cover for coolant leaks.If the oil seal is damage

COOLING SYSTEM 4-13Water Pump•Insert a bar [A] into the water pump shaft hole from theinside of the right engine cover, and remove the oil seal[B] by

1-6 GENERAL INFORMATIONBefore ServicingDirection of Engine RotationWhen rotating the c rankshaft by hand, the free playamount of rotating direction wi

4-14 COOLING SYSTEMRadiatorRadiator Removal•Drain the coolant (see Coolant Draining).•Remove:Bolts [A]Radiator Shrouds [B]•Loosen:Clamp Screws [A]•Rem

COOLING SYSTEM 4-15RadiatorRadiator Installation•Run the radiator hose [A] between the hot start cable,engine stop switch lead [B] and main harness [C

4-16 COOLING SYSTEMRadiatorRadiator Cap Inspection•Check the condition of the valve seals [A], and the top andbottom valve spring [B] of the radiator

ENGINE TOP END 5-15Engine Top E ndTable of ContentsExploded View... 5-2Specifications ...

5-2 ENGINE TOP ENDExploded View

ENGINE TOP END 5-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Auto-Decompressor Bolt 12 1.2 104 in·lb2 Cylinder Head Cover Bolts 9.8 1.0 87

5-4 ENGINE TOP ENDExploded View

ENGINE TOP END 5-5Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1Camshaft Chain Tensioner Mounting Bolts9.8 1.0 87 in·lb2 Camshaft Chain Tensio

5-6 ENGINE TOP ENDSpecificationsItem Standard Service LimitCamshaftsCam Height:Exhaust 33.941 ∼ 34.057 mm 33.84 mm(1.3363 ∼ 1.3408 in.) (1.3322 in.)In

ENGINE TOP END 5-7SpecificationsItem Standard Service LimitValve S eat Surface OutsideDiameter:Exhaust 24.62 ∼ 24.82 mm –––(0.9693 ∼ 0.9772 in.)Inlet

GENERAL INFORMATION 1-7Model IdentificationKX250T6F Left Side ViewKX250T6F Right Side View

5-8 ENGINE TOP ENDSpecificationsCam HeightCam Height [A]Camshaft RunoutValve Stem DiameterValve S tem Diameter [A]45° [B]Valve Stem BendDial Gauge [A]

ENGINE TOP END 5-9Special Tools & SealantsCompression Gauge, 20 kgf/cm²:57001-221Valve Spring Compressor Assembly:57001-241Piston Ring Compressor

5-10 ENGINE TOP ENDSpecial Tools & Sealant sSpark Plug Wrench, Hex 16:57001-1262Compression Gauge Adapter, M10 × 1.0:57001-1317Valve Seat Cutter,

ENGINE TOP END 5-11Special Tools & SealantsKawasaki Bond (Silicone Sealant):92104-0004

5-12 ENGINE TOP ENDCylinder Head CoverCylinder Head Cover Removal•Remove:Fuel Tank (see Fuel Tank Removal in the Fuel Systemchapter)Stick Coil (see Sp

ENGINE TOP END 5-13Camshaft Chain TensionerCamshaft Chain Tensioner RemovalCAUTIONThis is a non-return type camshaft chain tensioner.The push rod does

5-14 ENGINE TOP ENDCamshaftCamshaft Removal•Remove:Cylinder Head Cover (see Cylinder Head Cover Re-moval)Timing Inspection Cap [A]Flywheel Cap [B]Spec

ENGINE TOP END 5-15Camshaft•Remove:Bolt [A]Auto-Decompressor [B]Spring [C]Camshaft Installation•Install:Spring [A]Auto-Decompressor [B]Bolt [C]Torque

5-16 ENGINE TOP ENDCamshaft1st Pin [A] Punch Marks (exhaust) [D]2nd Pin [B] Punch Marks (inlet) [E]28th Pin [C] Upper Cylinder Head Surface [F]•Be sur

ENGINE TOP END 5-17Camshaft•Uniformly tighten all bolts and after the camshaft has set-tled, uniformly tighten all the bolts.○Bolts [A] are long.○Foll

1-8 GENERAL INFORMATIONGeneral SpecificationsItems KX250T6FDimensionsOverall Length 2 160 mm (85.04 in.)Overall Width 820 mm (32.3 in.)Overall Height

5-18 ENGINE TOP ENDCamshaftCamshaft and Camshaft Cap Wear•Measure each clearance between the camshaft journaland camshaft cap using plastigauge (press

ENGINE TOP END 5-19Cylinder HeadCylinder Compression Measurement•Start the engine.•Thoroughly warm up the engine so that the engine oil be-tween the p

5-20 ENGINE TOP ENDCylinder HeadCylinder Head Removal•Remove:Fuel Tank (see Fuel Tank Removal in the Fuel Systemchapter)Carburetor (see Carburetor Rem

ENGINE TOP END 5-21Cylinder Head•Pull the cylinder head upward.○Do not damage the radiator core.○Clear the front [A] and rear [B] chain guides.•Remove

5-22 ENGINE TOP ENDCylinder Head•Tighten the 6 mm bolts.M6 Cylinder Bolt [A]M6 Cylinder Head Bolt with Clamp [ B]M6 Cylinder Head Bolt [C]Torque - 6 m

ENGINE TOP END 5-23ValvesValve Clearance Inspection○Refer to the Valve Clearance Inspection in the PeriodicMaintenance chapter.Valve Removal•Remove th

5-24 ENGINE TOP ENDValvesValve Guide Removal•Remove:Valve(seeValveRemoval)Oil SealSpring Seat•Heat the area around the valve guide up to 120 ∼ 150°C(2

ENGINE TOP END 5-25Valves•Ream the valve guide with valve guide reamer [A], evenif the old guide is reused.○Always rotate the reamer clockwise.Special

5-26 ENGINE TOP ENDValvesValve Se at Inspection•Remove the valve (see Valve Removal).•Check the valve seating surface [A] between the valve [B]and val

ENGINE TOP END 5-27ValvesSeat Cutter Operation Care:1. This valve seat cutter is developed to grind the vale forrepair. Therefore the cutter must not

GENERAL INFORMATION 1-9General SpecificationsItems KX250T6FClutch TypeWet, multi disc, ManualTransmission:Type 5-speed, constant mesh, return shiftGea

5-28 ENGINE TOP ENDValves•Measure the outside diameter of the seating surface witha vernier caliper.If the outside diameter of the seating surface is

ENGINE TOP END 5-29Valves•The seating a rea should be marked about in the middleof the valve face.If the seat area is not in the right place on the va

5-30 ENGINE TOP ENDValvesValve Seat Repair

ENGINE TOP END 5-31Cylinder and PistonCylinder Removal•Remove:Cylinder Head (see Cylinder Head Removal)Front Camshaft Chain Guide [A]Cylinder Bolt [B]

5-32 ENGINE TOP ENDCylinder and Piston•Install the top ring [A] so that the "R" mark [B] faces up.NOTE○If a new piston or cylinder is used,

ENGINE TOP END 5-33Cylinder and Piston•Apply engine oil to the cylinder bore.•Determine the position of the piston ring ends.•Install the cylinder whi

5-34 ENGINE TOP ENDCylinder and PistonPiston Ring Groo ve Width•Measure the groove width at several points around thepiston with a vernier caliper.Pis

ENGINE TOP END 5-35Cylinder and PistonPiston, Piston Pin, Connecting Rod Wear Inspection•Visually inspect the snap ring [A] still fitted in place.If t

5-36 ENGINE TOP ENDCarburetor HolderCarburetor Holder Installation•Install the carburetor holder [A] with the marked [B] sidefacing toward the cylinde

ENGINE TOP END 5-37MufflerWARNINGTo avoid a serious burn, do not remove the mufflerwhen the engine is still hot. Wait until the mufflercools down.Muff

1-10 GENERAL INFORMATIONUnit Conversion TablePrefixes for Units:Prefix SymbolPowermega M × 1 000 000kilo k × 1 000centi c ×0.01milli m ×0.001micro µ ×

ENGINE RIGHT SIDE 6-16Engine Right SideTable of ContentsExploded View...

6-2 ENGINE RIGHT SIDEExploded View

ENGINE RIGHT SIDE 6-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1Primary Gear Nut98 10 72 LH2 Clutch Cover Bolts 9.8 1.0 87 in·lb3 Clutch Co

6-4 ENGINE RIGHT SIDEExploded View

ENGINE RIGHT SIDE 6-5Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1Kick Ratchet Guide Bolt8.8 0.9 78 in·lb L2 Kick Pedal Mounting Bolt 25 2.5

6-6 ENGINE RIGHT SIDESpecificationsItem Standard Service LimitClutch LeverClutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––ClutchFriction Plate Th

ENGINE RIGHT SIDE 6-7Special ToolsOutside Circlip Pliers:57001-144Clutch Holder:57001-1243Gear Holder, m2.0:57001-1557

6-8 ENGINE RIGHT SIDEClutch Lever and CableDue to friction plate wear and clutch cable stretch overa long period of use, the clutch must be adjusted i

ENGINE RIGHT SIDE 6-9Clutch Lever and Cable•Slide the dust covers [A] out of place.•Line up the slots [A] in the clutch lever [B], and adjuster[C] and

PERIODIC MAINTENANCE 2-12Periodic MaintenanceTable of ContentsPeriodic Maintenance Chart ...

6-10 ENGINE RIGHT SIDEClutch C over and Right Engine CoverClutch Cover Removal•Drain the engine oil at the transmission oil sump (see En-gine Oil Chan

ENGINE RIGHT SIDE 6-11Clutch Cover and Right Engine Cover•Remove:Water Pipe Bolt [A]Water Pipe [B]Water Pump Cover [C]•Remove the right engine cover b

6-12 ENGINE RIGHT SIDEClutch C over and Right Engine Cover•Install:Water Pump Cover (see Water Pump Cover Installationin the Cooling System chapter)•A

ENGINE RIGHT SIDE 6-13Clutch Cover and Right Engine Cover•Apply plenty of high temperature grease to the oil seallips.•Press in the oil seals directio

6-14 ENGINE RIGHT SIDEClutchClutch Removal•Drain the engine oil at the transmission oil sump (see En-gine Oil Change in the Periodic Maintenance chapt

ENGINE RIGHT SIDE 6-15Clutch•Install the clutch housing [A].○Turning the oil pump idle gear with the thin blade screw-driver [B] push in the clutch ho

6-16 ENGINE RIGHT SIDEClutch•If a clutch part was replaced, install the standard adjust-ing washer (1.5 mm thickness) [A] of the push rod holderassy,

ENGINE RIGHT SIDE 6-17ClutchClutch Spring Free Length Inspection•Measure the free length [A] of the clutch springs.If any clutch spring is shorter tha

6-18 ENGINE RIGHT SIDEPrimary GearPrimary Gear Removal•Remove:Right Engine Cover (see Right Engine Cover Removal)Clutch (see Clutch Removal)•Temporari

ENGINE RIGHT SIDE 6-19External Shift MechanismExternal Shift Mechanism Removal•Remove:Shift Pedal Bolt [A]Shift Pedal [B]•Remove:Right Engine Cover (s

2-2 PERIODIC MAINTENANCEDrive Chain Lubrication... 2

6-20 ENGINE RIGHT SIDEExternal Shift Mechanism•Set up the shift ratchet assembly as shown in the figure.Ratchet [A]Pawls [B]Pins [C]Springs [D]Crankca

ENGINE RIGHT SIDE 6-21External Shift Mechanism•Check the ratchet assembly for damage.If ratchet [A], pawls [B], pins [C] or springs [D] are dam-aged i

6-22 ENGINE RIGHT SIDEKickstarterKick Pedal Assy Removal•Remove:Mounting Bolt [A]Kick Pedal Assy [B]Kick Pedal Assy Installation•Install the kick peda

ENGINE RIGHT SIDE 6-23KickstarterIdle Gear Installation•Apply engine oil to the inside of the idle gear.•Install the washer [A].•Fit the idle gear [B]

6-24 ENGINE RIGHT SIDEKickstarterKickstarter Assembly Disassembly/Assembly•The kickstarter assembly consists of the following parts.•Check the kicksta

ENGINE LUBRICATION SYSTEM 7-17Engine Lubrication S ystemTable of ContentsExploded View...

7-2 ENGINE LUBRICATION SYSTEMExploded View

ENGINE LUBRICATION SYSTEM 7-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1Engine Oil Drain Plug M10 (for transmission roomoil sump)15 1.5 112

7-4 ENGINE LUBRICATION SYSTEMLubrication System Chart

ENGINE LUBRICATION SYSTEM 7-5Lubrication System Chart1. Oil Screen (scavenge)2. Oil Screen (feed)3. Oil Pump (scavenge)4. Oil Pump (feed)5. Right Cran

PERIODIC MAINTENANCE 2-3Periodic Maintenance ChartThe maintenance must be done in accordance with this chart to k eep the motorcycle in good runningco

7-6 ENGINE LUBRICATION SYSTEMSpecificationsItem StandardEngine OilGrade Castrol “R4 Superbike” 5W-40 or API SG, SH,SJ or SL with JASO MAViscosity SAE

ENGINE LUBRICATION SYSTEM 7-7Special ToolsOil Pressure Gauge, 5 kgf/cm²:57001-125Outside Circlip Pliers:57001-144Gear Holder, m2.0:57001-1557Oil Press

7-8 ENGINE LUBRICATION SYSTEMEngine Oil and Oil FilterWARNINGMotorcycle operation with insufficient, deteri-orated, or contaminated engine oil will ca

ENGINE LUBRICATION SYSTEM 7-9Engine Oil and Oil FilterOil Filter Change•Refer to the Engine Lubrication System in the PeriodicMaintenance chapter.Oil

7-10 ENGINE LUBRICATION SYSTEMOil PumpOil Pump Removal•Drain:Engine Oil (see Engine Oil Change in the Periodic Main-tenance chapter)Coolant (see Coola

ENGINE LUBRICATION SYSTEM 7-11Oil Pump•Remove the inner [A] and outer [B] rotors of the scavengeoil pump.•Disassemble the feed oil pump assembly.Oil P

7-12 ENGINE LUBRICATION SYSTEMOil Pump•Install the outer rotor [A].•Install the dowel pin [B] and dowel pin [C].•Install the scavenge and feed oil pum

ENGINE LUBRICATION SYSTEM 7-13Oil PressureOil Pressure Measurement•Start the engine and warm up the engine thoroughly.NOTE○Warm up the engine thorough

ENGINE REMOVAL/INSTALLATION 8-18Engine Removal/InstallationTable of ContentsExploded View...

2-4 PERIODIC MAINTENANCEPeriodic Maintenance ChartFREQUENCYOPERATIONEachrace or2.5 hrEvery 3races or7.5 hrEvery 6races or15 hrEvery 12races or30 hrSee

8-2 ENGINE REMOVAL/INSTALLATIONExploded View

ENGINE REM OVAL/INSTALLATION 8-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Upper Engine Mounting Bolt, Nut (M10) 49 5.0 362 Middle Engine

8-4 ENGINE REMOVAL/INSTALLATIONSpecial ToolsJack:57001-1238Attachment Jack:57001-1252Jack Attachment:57001-1608

ENGINE REM OVAL/INSTALLATION 8-5Engine Removal/InstallationEngine Removal•Place the jack [A] under the frame to support the motor-cycle.Special Tools

8-6 ENGINE REMOVAL/INSTALLATIONEngine Removal/Installation•Disconnect:Magneto Lead Connector [A]Neutral Switch Lead Connector [B]•Remove:Stick Coil [C

ENGINE REM OVAL/INSTALLATION 8-7Engine Removal/Installation•Remove:Middle Engine Bracket Bolts [A]Middle Engine Mounting Bolt [B]Middle Engine Bracket

8-8 ENGINE REMOVAL/INSTALLATIONEngine Removal/Installation•Install the removed parts.•Run the cables, hoses, and leads according to the Cable,Wire and

CRANKSHAFT/TRANSMISSION 9-19Crankshaft/TransmissionTable of ContentsExploded View...

9-2 CRANKSHAFT/TRANSMISSIONExploded View

CRANKSHAFT/TRANSMISSION 9-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRe-marks1Crankcase Bolts9.8 1.0 87 in·lbS2 Gear Set Lever Nut 8.8 0.9 78 in·l

PERIODIC MAINTENANCE 2-5Torque and Locking AgentTighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficientlytigh

9-4 CRANKSHAFT/TRANSMISSIONSpecificationsItem Standard Service LimitConnecting RodsConnecting Rod Big End Radial Clearance 0.002 ∼ 0.014 mm(0.00008 ∼

CRANKSHAFT/TRANSMISSION 9-5Special ToolsBearing Puller:57001-135Outside Circlip Pliers:57001-144Crankcase Splitting Tool Assembly:57001-1098Bearing Dr

9-6 CRANKSHAFT/TRANSMISSIONCrankcaseCrankcase Disassembly•Remove the engine from the frame (see Engine Re-moval/Installation in the E ngine Removal/In

CRANKSHAFT/TRANSMISSION 9-7Crankcase•Remove the crankcase bolts [A].•Install the jig [A] between the crankshaft flywheels [B].Special Tool - Crankshaf

9-8 CRANKSHAFT/TRANSMISSIONCrankcase•Remove:Shift Rods [A] (see Transmission Shaft Removal)3 S hift Forks [B] (see Transmission Shaft Removal)Shift Dr

CRANKSHAFT/TRANSMISSION 9-9Crankcase•Be sure to replace any oil seal removed with a new one.•Press in the new oil s eals using a press and bearing dri

9-10 CRANKSHAFT/TRANSMISSIONCrankcase•Press the new output shaft bearings [A] in the leftcrankcase half [B], so that the stepped side [C] facesinside

CRANKSHAFT/TRANSMISSION 9-11Crankcase•Install:Shift Drum [A] (see Transmission Installation)Shift Rods [B] (see Transmission Installation)Shift Forks

9-12 CRANKSHAFT/TRANSMISSIONCrankcase•Tighten the crankcase bolts, starting with the periphery ofthe crankshaft, then outward.○Tighten the [8], [12] b

CRANKSHAFT/TRANSMISSION 9-13Crankcase•Replace the O-rings [A] on the output shaft with new ones.•Install two O-rings on the grinding faces of the outp

2-6 PERIODIC MAINTENANCETorque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksRadiator Mounting Bolts 9.8 1.0 87 in·lbRadiator Shroud Bolts9.8 1

9-14 CRANKSHAFT/TRANSMISSIONCrankshaftCrankshaft Removal•Disassemble the crankcase (see Crankcase Disassem-bly).•Remove the transmission shaft (see Tr

CRANKSHAFT/TRANSMISSION 9-15Crankshaft•Carefully align the oil passage hole in the right flywheel[A] with the one in the crankpin [B] at rebuilding of

9-16 CRANKSHAFT/TRANSMISSIONCrankshaftCrankshaft Runout•Set the crankshaft in a flywheel alignment jig or on Vblocks, and place a dial gauge as shown

CRANKSHAFT/TRANSMISSION 9-17CrankshaftConnecting Rod Bend•Remove the connecting rod.•Select an arbor [A] of the same diameter as the connect-ing rod b

9-18 CRANKSHAFT/TRANSMISSIONTransmissionTransmission Shaft Removal•Disassemble the crankcase halves (see Crankcase Dis-assembly).•Pull out the oil scr

CRANKSHAFT/TRANSMISSION 9-19Transmission•Apply a small amount of engine oil to the shift fork fingersand fit each shift fork into the groove o f the p

9-20 CRANKSHAFT/TRANSMISSIONTransmission•The output shaft gears can be identified by size; thelargest diameter gear is 1st gear, and the smallest is5t

CRANKSHAFT/TRANSMISSION 9-21Transmission•Check each gear spins or slides freely on the transmissionshaft without binding after assembly.Shift Fork Ben

9-22 CRANKSHAFT/TRANSMISSIONBearings/Oil SealsBearing ReplacementCAUTIONDo not remove the ball bearings unless it is neces-sary. Removal may damaged t

CRANKSHAFT/TRANSMISSION 9-23Bearings/Oil Seals•Check the needle bearing.○The rollers in a needle bearing normally wear very little,and wear is difficu

PERIODIC MAINTENANCE 2-7Torque and Locking AgentTorqueFastenerN·mkgf·m ft·lbRemarksOil Filter C ap Bolts9.8 1.0 87 in·lbOil P ump Mounting Bolts7.0 0.

WHEELS/TIRES 10-110Wheels/TiresTable of ContentsExploded View...

10-2 WHEELS/TIRESExploded View

WHEELS/TIRES 10-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Spoke Nipples 2.2 0.22 19 in·lb2 Front Axle Nut 79 8.0 583 Front Axle Clamp Bo

10-4 WHEELS/TIRESSpecificationsItem Standard Service LimitWheels (Rims)Rim Runout:Axial 1.0 mm (0.039 in.) or less 2mm(0.08in.)Radial 1.0 mm (0.039 in

WHEELS/TIRES 10-5Special ToolsInside Circlip Plie r s:57001-143Rim Protector:57001-1063Bead Breaker Assembly:57001-1072Bearing Driver Set:57001-1129Ja

10-6 WHEELS/TIRESWheels (Rims)Front Wheel Removal•Using the jack [A] under the frame, and stabilize the mo-torcycle.Special Tools - Jack: 57001-1238Ja

WHEELS/TIRES 10-7Wheels (Rims)•Remove the jack.•Before tightening the clamp bolts on the right fork leg,pump the forks up and down [A] 4 or 5 times to

10-8 WHEELS/TIRESWheels (Rims)•Take off the collars [A] and caps [B] from the each side ofthe rear hub.CAUTIONDo not lay the wheel on the ground with

WHEELS/TIRES 10-9Wheels (Rims)•Check the drive chain slack (see Final Drive chapter).•Tighten the axle nut.Torque - Rear Axle Nut: 110 N·m (11.0 kg·m,

2-8 PERIODIC MAINTENANCETorque and Locking AgentTorqueFastenerN·m kgf·m ft·lbRemarksBrake Reservoir Cap Bolts 1.5 0.15 13 in·lbBrake Disc Mounting Bol

10-10 WHEELS/TIRESTiresTire RemovalCAUTIONDo not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.Place blocks u

WHEELS/TIRES 10-11Tires•Step on the side of the tire opposite valve stem, pry thetire off the rim with the tire iron [A] of the bead breakerprotecting

10-12 WHEELS/TIRESTires•Tighten the bead protector nut [A] and valve stem nut [B].•Check and adjust the air pressure after installing.•Putonthevalveca

WHEELS/TIRES 10-13Hub BearingsHub Bearing Removal•Remove the wheel (see Wheel Removal).CAUTIONDo not lay the wheel on the ground with the discfacing d

FINAL DRIVE 11-111Final DriveTable of ContentsExploded View...

11-2 FINAL DRIVEExploded View

FINAL DRIVE 11-3Exploded ViewTorqueNo FastenerN·m kgf·m ft·lbRemarks1 Rear Sprocket Nuts 34 3.5 252 Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb3. Eng

11-4 FINAL DRIVESpecificationsItem Standard Service LimitDrive ChainChain Slack 52 ∼ 58 mm (2.05 ∼ 2.28 in.)–––Chain 20-link Length 317.5 ∼ 318.2 mm (

FINAL DRIVE 11-5Special ToolsOutside Circlip Pliers:57001-144

PERIODIC MAINTENANCE 2-9Torque and Locking AgentTorqueFastenerN·mkgf·m ft·lbRemarksCrankshaft Sensor Bolts7.0 0.7 61 in·lbSpark Plug13 1.3 115 in·lbC.

11-6 FINAL DRIVEDrive ChainDrive Chain Slack Inspection•Refer to the Drive Chain Slack Inspection in the PeriodicMaintenance chapter.Drive Chain Slack

FINAL DRIVE 11-7Drive Chain•Install the clip [A] so that the closed end of the "U" [B]pointed in the direction of chain rotation [C].•Adjust

11-8 FINAL DRIVESprocketsEngine Sprocket Removal•Remove:Engine Sprocket Cover B olts [A]Engine Sprocket Cover [B]Drive Chain Guide [C]•Remove:Drive Ch

FINAL DRIVE 11-9SprocketsRear Sprocket Installation•Install the rear sprocket [A] so that the marked side [B]faces out.•Install the rear sprocket bolt

BRAKES 12-112BrakesTable of ContentsExploded View...

12-2 BRAKESExploded View

BRAKES 12-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Front Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb S2 Brake Hose Banjo Bolts 34 3.5

12-4 BRAKESExploded View

BRAKES 12-5Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Brake Hose Banjo Bolts 34 3.5 252 Rear Master Cylinder Mounting Bolts 10 1.0 87 in·l

2-10 PERIODIC MAINTENANCESpecificationsItem Standard Service LimitFuel SystemThrottleGripFreePlay 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––Hot Start Lever Free P

12-6 BRAKESSpecificationsItem Standard Service LimitBrake adjustmentLever Play Adjustable (to suit rider) –––Brake FluidRecommended Disc Brake Fluid:

BRAKES 12-7Special ToolsInside Circlip Plie r s:57001-143

12-8 BRAKESBrake Lever, B rake PedalBrake Lever Play Adjustment•Refer to the Brake Lever Play Adjustment in the PeriodicMaintenance chapter.Brake Peda

BRAKES 12-9Brake FluidWARNINGWhen working with the disc brake, observe the pre-cautions listed below.1. Never reuse old brake fluid.2. Do not use flui

12-10 BRAKESBrake F luidBleeding the Brake LineThe brake fluid has a very low compression coefficient sothat almost all the movement of the brake leve

BRAKES 12-11Brake Fluid•Bleed the brake line and the caliper as follows:○Repeat this operation until no more air can be seen com-ing out into the plas

12-12 BRAKESCaliperCaliper RemovalFront Brake:•Loosen the banjo bolt [A] so as not to spill brake fluid.•Remove the caliper mounting bolts [B].•Remove

BRAKES 12-13Caliper•Bleed the brake line (see Bleeding the Brake Line).•Check the brake for good braking power, no brake drag,and no fluid leakage.WAR

12-14 BRAKESCaliperBrake Pad RemovalFor Front Brake Pad•Unscrew the pad bolt [A].•Take the piston side pad [B].•Push the caliper holder toward the pis

BRAKES 12-15Caliper•Tighten the brake pad bolt.Torque - Brake Pad Bolt: 17 N·m (1.7 kgf·m, 12.5 ft·lb)Brake Pad Bolt Plug: 2.5 N·m (0.25 kgf·m, 22 in·

PERIODIC MAINTENANCE 2-11SpecificationsItem Standard Service LimitStandard Tire:Front:Size 80/100-21 51M –––Make BRIDESTONE –––Type M401, Tube, –––(EU

12-16 BRAKESMaster CylinderCAUTIONBrake fluid quickly ruins painted or plastic sur-faces; any spilled fluid should be completelywished up immediately.

BRAKES 12-17Master Cylinder•The master cylinder clamp must be installed with the ar-row mark [A] upward.○Tighten the upper clamp bolt [B] first, and t

12-18 BRAKESMaster Cylinder•Replace the cotter pin with a new one.•Install the joint pin, washer and a new cotter pin.•Bend the ends [A] of the cotter

BRAKES 12-19Master CylinderMaster Cylinder Insp ection (Visual Inspection)•Disassemble the front and rear master cylinders.•Check that there are no sc

12-20 BRAKESBrake DiskBrake Disc Inspection•Visually inspect the disc [A].If it is scratched or damaged, replace the disc.•Measure the thickness of ea

BRAKES 12-21Brake HoseBrake Hose Removal/Installation•Refer to the Brake Hose Replacement in the PeriodicMaintenance chapter.Brake Hose Inspection•Ref

SUSPENSION 13-113SuspensionTable of ContentsExploded View... 13-2Specifications ... 1

13-2 SUSPENSIONExploded View

SUSPENSION 13-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Front Fork Cylinder 34 3.5 252 Front Fork Lower Clamp Bolts 20 2.0 14.5 AL3 Fron

This quick reference guide will assistyou in locating a desired topic or pro-cedure.•Bend the pages back to match theblack tab of the desired chapter

2-12 PERIODIC MAINTENANCESpecial ToolsInside Circlip Pliers:57001-143Steering Stem Nut Wrench:57001-1100Jack:57001-1238Attachment Jack:57001-1252Spark

13-4 SUSPENSIONExploded View

SUSPENSION 13-5Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Swingarm P ivot Shaft Nut 98 10 722 Rocker Arm Pivot Nut 83 8.5 613 Tie-rod Moun

13-6 SUSPENSIONSpecificationsItem Standard Service LimitFront ForkAir Pressure Atmospheric pressure –––Rebound Damping Adjustment (Adjustable Range)(f

SUSPENSION 13-7Special ToolsOil Seal & Bearing Remover:57001-1058Hook Wrench R37.5, R42:57001-1101Bearing Driver Set:57001-1129Jack:57001-1238Atta

13-8 SUSPENSIONSpecial ToolsFork O il Seal Driver, 47:57001-1662

SUSPENSION 13-9Front ForkAir PressureThe standard air pressure in the front fork legs is atmo-spheric pressure. Air pressure in the fork legs increase

13-10 SUSPENSIONFront ForkCompression Damping Adjustment•Place the jack under the frame so that the front wheel offthe ground.Special Tools - Jack: 57

SUSPENSION 13-11Front Fork•Rest the caliper [B] on some kind of stand [A] so that itdoesn’t dangle.•Loosen the upper [A], and lower fork clamp bolts [

13-12 SUSPENSIONFront Fork•Route the cables and hose according to the Cable, Har-ness, Hose Routing section in the Appendix chapter.•Unscrew the upper

SUSPENSION 13-13Front Fork•Unscrew the fork cylinder unit [A] from the outer tube [B].•Slowly slide down the outer tube.•Hold the fork tube [A] upside

PERIODIC MAINTENANCE 2-13Periodic Maintenance ProceduresFuel SystemFuel Hose and Connection Inspection○If the motorcycle is not properly handled, the

13-14 SUSPENSIONFront Fork•Hold the locknut [A] with a wrench [B] and remove theadjuster assembly [C].NOTE○Do not remove the locknut from the piston r

SUSPENSION 13-15Front Fork•Holding the top plug wrench [A] with a vise, unscrew thebase valve assembly [B] on the fork cylinder unit [C].○Use the hexa

13-16 SUSPENSIONFront Fork•Unscrew the locknut [A].•Wrap the end of the piston rod with a vinyl tape [B].•Push the piston rod [C] into the cylinder [D

SUSPENSION 13-17Front Fork•Remove the guide bushes [A], washer [B], oil seal [C],retaining ring [D], and dust seal [E] from the inner tube.•Wipe off t

13-18 SUSPENSIONFront Fork○Turningin[A]thepistonrodwithawrench[B].•Remove a vinyl tape and install the locknut.•Clean the threads [A] of the fork cyli

SUSPENSION 13-19Front Fork•Replace the O-ring [A] on the base valve assembly withnew ones.•Apply fork oil to the O-rings and bushings [B].CAUTIONDo no

13-20 SUSPENSIONFront Fork•Check the compression damping force setting to the soft-est.•Check the piston rod sliding surface for damage.•Drain the ext

SUSPENSION 13-21Front Fork•There should be no oil leak from the base valve assemblypart [A] or bottom [B] of the cylinder.If oil leaks from the base v

13-22 SUSPENSIONFront Fork•Compress the outer tube by hands and insert the t op plugwrench [A] between the axle holder part bottom [B] andlocknut [C].

SUSPENSION 13-23Front Fork•Compare the length [A] at assembly and at disassembly.○There should be same length.If the length at assembly is longer than

2-14 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresIf the throttle grip free play cannot be adjusted with theadjuster, replace the throttle cable

13-24 SUSPENSIONFront ForkThe torque of fork cylinder unit is specified to 34 N·m (3.5kgf·m, 25 ft·lb) however, when you use the top plug wrench[A], r

SUSPENSION 13-25Front ForkSlide/Guide Bushing Inspection•Visually inspect the guide bushing [A], and replace themif necessary.Dust Seal/Oil Seal Inspe

13-26 SUSPENSIONRear Suspension (Uni-Trak)Rear Shock AbsorberThe rear suspension system of this motorcycle is NewUni-trak. It consists of a rear shock

SUSPENSION 13-27Rear Suspension (Uni-Trak)•Adjust the high speed compression damping, turn thehigh speed compression damping adjuster with a 17 mmwren

13-28 SUSPENSIONRear Suspension (Uni-Trak)•Using the hook wrenches [A], loosen the locknut [B] onthe rear shock absorber.Special Tools - Hook Wrench R

SUSPENSION 13-29Rear Suspension (Uni-Trak)Rear Shock Absorb er Removal•Remove:Seat (see Seat Removal in the Frame chapter)Side Covers (see Side Cover

13-30 SUSPENSIONRear Suspension (Uni-Trak)•Hold the upper end of the rear shock absorber in a visewith soft jaws [A] or a heavy cloth.•Using the hook

SUSPENSION 13-31SwingarmSwingarm Removal•Place the jack [A] under the frame so that the rear wheelis off the ground.Special Tools - Jack: 57001-1238Ja

13-32 SUSPENSIONSwingarmSwingarm Bearing Removal•Remove:SwingarmCollars [A]Grease Seals [B]Sleeves [C]Needle Bearings [D]•Remove the needle bearings [

SUSPENSION 13-33Swingarm•Visually inspect the upper and lower chain guide rollers[A] and replace them if excessively worn or damaged.Swingarm Bearin g

PERIODIC MAINTENANCE 2-15Periodic Maintenance Procedures•Start the engine and warm it up thoroughly.•With the engine idling, turn the handlebar to bot

13-34 SUSPENSIONTie-Rod, Rocker ArmTie-Rod Removal•Using the jack under the frame, raise the rear wheel offthe ground.Special Tools - Jack: 57001-1238

SUSPENSION 13-35Tie-Rod, Rocker Arm•Remove the tie-rod rear mounting bolt [A].•Remove:Rear Shock Absorber Lower Mounting Bolt [A]Rocker Arm Pivot Shaf

13-36 SUSPENSIONTie-Rod, Rocker ArmTie-Rod and Rocker Arm Bearing Removal•Remove:Tie-Rod(seeTie-RodRemoval)Rocker Arm (see Rocker Arm Removal)Washers

SUSPENSION 13-37Tie-Rod, Rocker Arm•Install the needle bearings [A], [B], grease seals [C], andoil seals [D] position as s hown.○The installation proc

13-38 SUSPENSIONUni-Trak MaintenanceUni-Trak Linkage Inspection•Refer to the Uni-Trak Linkage Inspection in the PeriodicMaintenance chapter.Tie-Rod an

STEERING 14-114SteeringTable of ContentsExploded View...

14-2 STEERINGExploded View

STEERING 14-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Handlebar Clamp Bolts 25 2.5 18.0 S2 Steering Stem Head Nut 98 10 723 Steering Ste

14-4 STEERINGSpecial ToolsBearing Puller Adapter:57001-317Steering Stem Bearing Driver:57001-137Steering Stem Bearin g Driver Adapter, 34.5:57001-1074

STEERING 14-5SteeringSteering Inspection•Refer to the Steering Inspection in the Periodic Mainte-nance chapter.Steering Adjustment•Refer to the Steeri

2-16 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Start the engine and warm it up thoroughly.•Turn the idle adjusting screw [A] until the idle

14-6 STEERINGSteering•Pushing up on the stem base [A], and remove the steeringstem nut [B], with the steering stem nut wrench [C], thenremove the stee

STEERING 14-7Steering•Replace the lower inner races with new ones.○Apply grease to the lower tapered roller bearing [A], anddrive it onto the stem usi

14-8 STEERINGSteering•Install the parts removed.WARNINGDo not impede the handlebar turning by routing thecables, wires and hoses improperly (see the G

STEERING 14-9HandlebarHandlebar Removal•Remove:Band [A]Pad Cover and Pad [B]•Remove:Clutch Lever Holder Assembly [A]Engine Stop Switch [B]Bands [C]Lef

14-10 STEERINGHandlebar•Install the clutch lever holder assembly [A] position asshown in the figure.[B] 170 mm[C] Horizontal Line of Frame[D] H andleb

STEERING 14-11Handlebar○Install the master cylinder [A] position as shown in thefigure.[B] 185 mm (7.28 in.)[C] Horizontal Line of Frame[D] Handlebar[

FRAME 15-115FrameTable of ContentsExploded View...

15-2 FRAMEExploded View

FRAME 15-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Upper Rear Frame Mounting Bolt 34 3.5 252 Lower Rear Frame Mounting Bolts 34 3.5 253

PERIODIC MAINTENANCE 2-17Periodic Maintenance Procedures•Separate the element [A] from the frame [B].•Clean the element [A] in a bath of a high-flash-

15-4 FRAMEFrameFrame Inspection•Refer to the Frame Inspection in the Periodic Mainte-nance chapter.Rear Frame Removal•Remove:Seat (see Seat Removal)Ri

FRAME 15-5Frame•Insert the duct end [A] slantly between the frame [B] andupper portion [C] of the shock absorber.•Install the rear frame upper mountin

15-6 FRAMESeatSeat Removal•Unscrew the bolts [A].•Pull the seat [B] out from the back.Seat Installation•Fit the hooks [A] of the seat under the flange

FRAME 15-7Side CoverSide Cover Removal•Unscrew the bolts [A] and remove the side cover.Side Cover Installation•Stick the pads [A] on the inside of the

15-8 FRAMEFenderFront Fender Removal•Unscrew the bolts [A] and remove the front fender [B].Rear Fender Removal•Remove:Seat•Unscrew the bolts [A] and r

ELECTRICAL SYSTEM 16-116Electrical SystemTable of ContentsExploded View...

16-2 ELECTRICAL SYSTEMExploded View

ELECTRICAL SYSTEM 16-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Neutral Switch 12 1.2 104 in·lb2 Flywheel Nut 49 5.0 363 Stator Bolts 7.0

16-4 ELECTRICAL SYSTEMSpecificationsItem StandardMagnetoCrankshaft Sensor Resistance 80 ∼ 120 ΩMagneto Output Voltage in the textStator Coil Resistanc

ELECTRICAL SYSTEM 16-5Special ToolsTiming Light:57001-1241Hand Tester:57001-1394Throttle Sensor Setting Adapter #1:57001-1400Peak Voltage Adapter:5700

2-18 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Install the air cleaner element so that its tab [A] facesupward and its projections [B] align

16-6 ELECTRICAL SYSTEMWiring Diagram

ELECTRICAL SYSTEM 16-7PrecautionsThere are numbers of important precautions that aremusts when servicing electrical systems. Learn and ob-serve all th

16-8 ELECTRICAL SYSTEMElectrical WiringWiring Inspection•Visually inspect the wiring for signs of burning, fraying,etc.If any wiring is poor, replace

ELECTRICAL SYSTEM 16-9Flywheel MagnetoMagneto Cover Removal•Drain the engine oil from the crank room oil sump (seeEngine Oil Change in the Periodic Ma

16-10 ELECTRICAL SYSTEMFlywheel Magneto•Hold the flywheel steady, with the rotor holder [A], andremove the nut [B].Special Tool - Rotor Holder: 57001-

ELECTRICAL SYSTEM 16-11Flywheel MagnetoStator Removal•Remove:Magneto Cover (see Magneto Cover Removal)Stator Bolts [A]Crankshaft Sensor Bolts [B]Wirin

16-12 ELECTRICAL SYSTEMFlywheel Magneto○Connect the hand tester [A] to the connector [B] as shownin the table 1, using the needle adapter set [C].○Sta

ELECTRICAL SYSTEM 16-13Ignition TimingIgnition Timing Inspection•Remove the timing inspection cap [A].Special Tool - Filler Cap Driver: 57001-1454•Att

16-14 ELECTRICAL SYSTEMIgnition SystemSafety InstructionsWARNINGThe ignition system produces extremely high volt-age. Do not touch the stick coil whil

ELECTRICAL SYSTEM 16-15Ignition SystemSpark Plug G ap Inspection•Refer to the Spark Plug Gap Inspection in the PeriodicMaintenance chapter.C.D.I. Unit

PERIODIC MAINTENANCE 2-19Periodic Maintenance ProceduresCooling SystemWARNINGTo avoid burns, do not remove the radiator cap ortry to change the coolan

16-16 ELECTRICAL SYSTEMIgnition SystemStick Coil Primary Peak Voltage Check•Disconnect the stick coil from the spark plug, but do notremove the spark

ELECTRICAL SYSTEM 16-17Ignition SystemTrouble shooting chart

16-18 ELECTRICAL SYSTEMIgnition SystemCrankshaft Sensor Peak Voltage Check•To check the peak voltage, do the following procedures.○Disconnect the conn

ELECTRICAL SYSTEM 16-19Ignition SystemCharge Coil Peak Voltage Check•Disconnect the connector of the magneto lead connectorfrom the m ain harness.•To

16-20 ELECTRICAL SYSTEMIgnition System•To check the output voltage, do the following procedures.○Connect the digital voltmeter as follows.Tester (+) →

ELECTRICAL SYSTEM 16-21Throttle SensorThrottle Sensor InspectionNOTE○If the variable rheostat is not available, refer to throttlesensor output/input v

16-22 ELECTRICAL SYSTEMThrottle SensorThrottle Sensor Position Adjustment•Remove the carburetor (see Carburetor Removal in theFuel System chapter).•Me

ELECTRICAL SYSTEM 16-23Neutral SwitchNeutral Switch I nspection•Slide out the dust cover [A].•Disconnect the connector [B].○Unscrew the screw.•Using a

APPENDIX 17-117AppendixTable of ContentsCable, Wire, and Hose Routing...

2-20 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresCAUTIONFor refilling, add the specified mixture of coolantand soft water. Adding water alone d

17-2 APPENDIXCable, Wire, and Hose Routing1. Throttle Cables2. Marked (AAA) cable is accelerator side.3. Band (Hold the engine stop switch lead.)4. En

APPENDIX 17-3Cable, Wire, and Hose Routing1. Clutch Cable2. Engine Stop Switch Lead3. C.D.I. Unit4. Main Harness5. Frame Ground6. Clamps (Run the clut

17-4 APPENDIXCable, Wire, and Hose Routing1. C.D.I. Unit2. Main Harness3. Clamp (Run the hot start cable and mainharness.)4. Neutral Switch Lead Conne

APPENDIX 17-5Cable, Wire, and Hose Routing1. Clumps (Position the clamp claw front.)2. Install the upper radiator tube so that theyellow painted mark

17-6 APPENDIXCable, Wire, and Hose Routing1. Run the fuel hose inside the hot start cable.2. Align the end of the net protector with the cam chain ten

APPENDIX 17-7Cable, Wire, and Hose Routing1. Brake Lever2. Front Brake Master Cylinder3. Front Brake Hose4. Clamp5. Viewed6. Clamps7. Front Brake Cali

17-8 APPENDIXTroubleshooting GuideThis is not an exhaustive list, giving e verypossible cause for each problem listed. it ismeant simply as a rough gu

APPENDIX 17-9Troubleshooting GuideDrive train troubleEngine overheatingClutch slippingPoor Running or No Power at HighSpeed:Firing incorrect:Spark plu

17-10 APPENDIXTroubleshooting GuideClutch housing seizedClutch release function troubleClutch hub nut looseClutch plate warped or roughClutch hub spli

APPENDIX 17-11Troubleshooting GuideValve guide wornEngine oil level too highBlack smoke:Air cleaner element cloggedMain jet too large or fallen offSta

PERIODIC MAINTENANCE 2-21Periodic Maintenance ProceduresEngine Top EndValve Clearance InspectionNOTE○Valve clearance must be checked and adjusted when

MODEL APPLICATIONYear Model Beginning Frame No.2006 KX250T6FJKAKXMTC□6A000001 orJKAKX250TTA000001□:This digit in the frame number changes from one mac

2-22 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresNOTE○Mark and record the locations of the valve lifters andshims so that they can be reinstall

PERIODIC MAINTENANCE 2-23Periodic Maintenance ProceduresCAUTIONBe sure to remeasure the clearance after selectinga shim. The clearance can be out of t

2-24 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresCylinder Wear InspectionNOTE○Measure the cylinder inside diameter when the cylinderis cold (ro

PERIODIC MAINTENANCE 2-25Periodic Maintenance ProceduresExhaust System Inspection•The exhaust system, in particular the silencer, i s designedto reduc

2-26 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Install the end [A] of the silencer pipe [B] to the baffle [C].•Apply a non-permanent locking

PERIODIC MAINTENANCE 2-27Periodic Maintenance ProceduresClutch Lever Free Play Adjustment•Turn the adjuster [A] so that the clutch lever [B] will have

2-28 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresEngine Lubrication SystemWARNINGMotorcycle operation with insufficient, deteri-orated, or cont

PERIODIC MAINTENANCE 2-29Periodic Maintenance ProceduresOil Filter Change•Drain:Engine Oil (see Engine O il Change)•Remove:Oil Filter Cap Bolt [A]Oil

2-30 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresCrankshaft/TransmissionCrankshaft Inspection•Make sure that the crankshaft rotate smoothy (in

PERIODIC MAINTENANCE 2-31Periodic Maintenance ProceduresTires InspectionAs the tire tread wears down, the tire becomes more sus-ceptible the puncture

KX250FMotorcycleService ManualAll rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, ortransmitted in any

2-32 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresRim Runout Inspection•Place the jack under the frame so that the front/rear wheeloff the groun

PERIODIC MAINTENANCE 2-33Periodic Maintenance Procedures•Turn the handlebar until the handlebar doesn’t move toeither side.•The wheel edge is moved to

2-34 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresDrive Chain Slack Inspection•Raise the rear wheel off the ground, rotate the rear wheelto find

PERIODIC MAINTENANCE 2-35Periodic Maintenance ProceduresNOTE○When inserting the cotter pin, if the slots in the nut donot align with the cotter pin ho

2-36 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresSprocket Wear Inspection•Visually inspect the front and rear sprocket teeth for wearand damage

PERIODIC MAINTENANCE 2-37Periodic Maintenance ProceduresNOTE○Usually it is not necessary to adjust the pedal position,but always adjust it when the ma

2-38 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresBrake Fluid Level Inspection•Check the brake fluid level in the front or rear brake reser-voir

PERIODIC MAINTENANCE 2-39Periodic Maintenance ProceduresBrake Fluid ChangeIn accordance with the Periodic Maintenance Chart,change the brake fluid. Th

2-40 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresNOTE○The procedure to change the front brake fluid. Chang-ing the rear brake fluid is the same

PERIODIC MAINTENANCE 2-41Periodic Maintenance Procedures•Remove the clear plastic hose.•Tighten the bleed valves, and install the rubber caps.Torque -

LIST OF ABBREVIATIONSA ampere(s) lb pound(s)ABDC after bottom dead center m meter(s)AC alternating current min minute(s)ATDC after top dead center N n

2-42 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Remove the reservoir cap and diaphragm, and pour thebrake fluid into a container.•Slide the d

PERIODIC MAINTENANCE 2-43Periodic Maintenance Procedures•Separate the caliper holder [A] from the caliper [B] andremove the anti-rattle spring.•Using

2-44 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Pull out the piston [A] by hand.•Remove the dust seal [B] and fluid seal [C].•Clean the calip

PERIODIC MAINTENANCE 2-45Periodic Maintenance Procedures•Replace the shaft rubber friction boot [A] and dust boot[B] if they are damaged.•Apply a thin

2-46 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Remove each banjo bolts [A] and washers [B].•Replace the washers with new ones.For Front Brak

PERIODIC MAINTENANCE 2-47Periodic Maintenance ProceduresSuspensionFront Fork Inspection•Holding the brake lever, pump the front fork back and forthman

2-48 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Loosen the front fork lower clamp bolts [A].•Remove the front fork.○With a twisting motion, w

PERIODIC MAINTENANCE 2-49Periodic Maintenance Procedures•Temporarily install t he fork cylinder unit [A] to the outertube [B].Special Tool - Top Plug

2-50 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•With the outer tube compressed by hand, remove the topplug wrench.CAUTIONRemoving the locknut

PERIODIC MAINTENANCE 2-51Periodic Maintenance Procedures•Hold the fork cylinder unit [A] upside down over a cleancontainer [B] and pump it to drain th

ForewordThis manual is designed primarily for use bytrained mechanics in a properly equipped shop.However, it contains enough detail and basic in-form

2-52 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•With the piston rod fully stretched, check the oil level inthe fork cylinder unit.○Measure th

PERIODIC MAINTENANCE 2-53Periodic Maintenance Procedures•Discharge the extra oil off the cylinder unit [A] by pumpingthe piston rod [B] to full stroke

2-54 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Wipe the oil off completely from the cylinder unit [A].•Compress the piston rod [B] to 200 ∼

PERIODIC MAINTENANCE 2-55Periodic Maintenance Procedures•Compress the outer tube by hands and insert the top plugwrench [A] between the axle holder pa

2-56 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Compare the length [A] at assembly and at disassembly.○There should be same length.If the len

PERIODIC MAINTENANCE 2-57Periodic Maintenance ProceduresThe torque of fork cylinder unit is specified to 34 N·m (3.5kgf·m, 25 ft·lb) however, when you

2-58 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresWARNINGDo not to point the reservoir valve toward your faceor body when releasing nitrogen gas

PERIODIC MAINTENANCE 2-59Periodic Maintenance Procedures•Slide the stop up the top of the piston rod then lightly taparound the seal with a s uitable

2-60 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Inspect the slide bushing [A].If the bushing is damaged, replace it.•Cut the slide bushing [A

PERIODIC MAINTENANCE 2-61Periodic Maintenance Procedures•Replace the following with new ones.Oil SealsRebound Rubber (if damaged)O-ring•Install each p

2-62 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Install:Damper Holder [A]Damper [B]Stopper [C]•Wrap the threads of the piston rod with tape [

PERIODIC MAINTENANCE 2-63Periodic Maintenance Procedures○Install the piston direction as shown in the figure.Locknut Side Face [A]•Stake [A] the end o

2-64 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Mount the c irclip [A] in the groove in the gas reservoir.•Pull up the gas reservoir cap [A]

PERIODIC MAINTENANCE 2-65Periodic Maintenance Procedures•Force the stop [A] into the rear shock body by lightly tap-ping around the edge of the stop w

2-66 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Inject nitrogen gas to a pressure of 50 kPa (0.5 kgf/cm²,7 psi) through the valve on the gas

PERIODIC MAINTENANCE 2-67Periodic Maintenance Procedures•Push and pull on the swingarm [A] to check for wear.A small amount of play on the swingarm is

2-68 PERIODIC MAINTENANCEPeriodic Maintenance Procedures•Slide the holder belt [A] out off.•Remove:Number Plate Bolt [B]Number Plate [C]Handlebar Pad

PERIODIC MAINTENANCE 2-69Periodic Maintenance Procedures•Check the steering again.If the steering is too tight or too loose, repeat the adjust-ment as

2-70 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresFrameFrame Inspection•Clean the frame with steam cleaner.•Visually inspect the frame and rear

PERIODIC MAINTENANCE 2-71Periodic Maintenance Procedures•Measure the gap [A] with a wire-type thickness gauge.If the gap is incorrect, carefully bend

GENERAL INFORMATION 1-11General InformationTable of ContentsBefore Servicing ...

2-72 PERIODIC MAINTENANCEPeriodic Maintenance ProceduresCables: Lubricate with Rust Inhibitor.Throttle CablesClutch CableHot S tart CablePivots: Lubri

PERIODIC MAINTENANCE 2-73Periodic Maintenance ProceduresIf there are loose fasteners, retorque them to the specifiedtorque following the specified tig

FUEL SYSTEM 3-13Fuel SystemTable of ContentsExploded View...

3-2 FUEL SYSTEMExploded View

FUEL SYSTEM 3-3Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Throttle Pulley Cover Bolt 3.4 0.3 30 in·lb2 Throttle Cable Locknut 7.0 0.7 61 i

3-4 FUEL SYSTEMExploded View

FUEL SYSTEM 3-5Exploded ViewTorqueNo. FastenerN·m kgf·m ft·lbRemarks1 Rear Frame Mounting Bolts 34 3.5 252 Air Cleaner Duct Clamp Screw 3.0 0.3 27 in·

3-6 FUEL SYSTEMSpecificationsItem Standard Service LimitCarburetorMake/Type KEIHIN FCR37 –––Starter Jet #68 –––Leak Jet #60 –––Main Je t#180, (EUR) #1

FUEL SYSTEM 3-7Special ToolsFuel Level Gauge, M18 × 1.0:57001-122