Owner's Manuals. Manual Description Any of the following front fork adjustments should be made to tune the front suspension to the rider's weight and the condition of the track. Basically, there are six adjustments you can make to the front fork. Air pressure acts as a progressive spring over the entire fork travel range. Since the air pressure in the fork legs increases with normal use, the fork action on your KX will get stiffer as the race progresses.

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Quick Links. Table of Contents. Page 5 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. Special tools, gauges, and venient operation. Model Identification General Specifications To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

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.

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. Ro- tate the crankshaft to positive direction clockwise viewed from output side. Electrical Leads A two-color lead is identified first by the primary color and then the stripe color. Overall Width mm Overall Height 1 mm Wheelbase 1 mm Road Clearance mm Rear mm 8.

Specifications are subject to change without notice, and may not apply to every country. Cylinder Unit 8. Fork Spring 2. Outer Chamber 9. Travel Control Valve 3. Oil Chamber Inner Tube 4. Oil Seal Transmission Oil Level Inspection Specifications Transmission Oil Change I Unit Mounting Bolts Cooling System Make the necessary free play adjustment at the lower cable adjuster, tighten the locknut [B], and install the boot.

A dirty or improperly oiled element can diminish engine performance, cause spark plug fouling, and could affect long term durability of the engine. Do not wring the ele- ment or blow it dry; the element can be damaged. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvent to clean the tank. Change the coolant in accordance with the Periodic Maintenance Chart. WARNING To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot.

The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced. If only a piston is replaced, the clearance may exceed the standard slightly.

If carbon has built up inside the baffle, ex- haust efficiency is reduced, causing engine performance to drop. If any plates show signs of damage, replace the friction plates and steel plates as a set. Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from the recom- mended pressure. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 2. If the chain is too tight, turn in the left and right chain adjusting bolts [D] evenly, and push the wheel forward until the chain is too loose.

If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. If they are worn as illustrated or damaged, replace the sprocket.

Worn Tooth Engine Sprocket B. Worn Tooth Rear Sprocket C. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed. Chang- ing the rear brake fluid is the same as for the front brake. Open the bleed valve [A] 2.

If necessary, repair any damage. Page 68 [A]. Do not disassemble the cylinder unit. Page 72 Make sure about 16 mm 0. If necessary, replace it with a new one. Do not insert the seal assembly [B] yet. Pump the piston rod until all the air is forced out of the rear shock body. If the gap is incorrect, replace it with the standard plug. Spark Plug Gap 0. Also, check to see that each cotter pin is in place and in good condition. Special Tool Throttle Grip and Cable Free Play Inspection Free Play Adjustment Throttle Cable Installation Throttle Cable Lubrication Idle Speed Inspection Idle Speed Adjustment Throttle Cable 6.

Fuel Tank Cap 6. Also, the throttle valve may not open fully at full throttle. Page Carburetor FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture too much fuel , and too lean a mixture too little fuel. Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber.

Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 6. Check to see that the throttle valve [B] goes all the way down into the carburetor body, and slides smoothly. If any water or dirt comes out, clean the carburetor, fuel tap and fuel tank see this chapter.

If the fuel level is incorrect, inspect the rest of the carbu- retor before correcting it. Also, coat the base where the lip of the element fits. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; Coolant Level Inspection Coolant Deterioration Inspection Coolant Draining Coolant Filling Air Bleeding Cooling System Pressure Testing Cooling System Flushing Disassembly and Assembly Precautions Change the coolant in accordance with the Periodic Maintenance Chart see Periodic Maintenance chapter.

When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the effi- ciency of the cooling system. If the surface is corroded, or if the blades [B] are dam- aged, replace the impeller.


Kawasaki KX250 Service Manual

Beginning Frame No. This quick reference guide will assist you in locating a desired topic or procedure. Motorcycle Service Manual All rights reserved. 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.


2003 Kawasaki KX250 — Owner's Manual



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