Motorcycle Assembly & Preparation Manual
Contents
1. AA WARNING H not removed the anticorrosive treat ment applied to the brake disc surface will interfere with brake action and an unsafe riding condition could result ND41B014 Preparation Air Cleaner Air Cleaner Element Inspection The foam cleaner element on off road models is oiled prior to shipping however over time the filter will dry and filtration performance will diminish e Remove the seat mounting bolts left and right 2 to remove the seat ME35003BS1 C A Seat B Bolt e Inspect the foam air cleaner element for proper oiling e f the foam air cleaner element is dry remove the wing bolt and take out the air cleaner element VDO9001BM2 C A Air Cleaner Element B Wing Bolt Take the element off its holder VD09002BM2 C A Air Cleaner Element B Holder e Saturate the element with high quality foam air filter oil and make sure that the oil is evenly applied throughout the element Squeeze out the excess oil but do not wring the element as this could cause tearing In this case too much oil is better than too little Finally pat the inside of the element with a paper towel to remove any excess oil e Install the element onto its holder and coat the element lip and lip seat with a thick layer of all purpose grease to assure a complete seal VDO9005BM2 C A Apply Grease PREPARATION 17 e Install the air cleaner element2. OThe coolant originally filled into the cooling system contains 50 of a permanent ethy lene glycol based antifreeze has a freezing point of 35 C 31 F and a green appear ance Coolant Level Inspection e Lean the motorcycle slightly to the left until the radiator cap is level to the ground e Loosen the bolts D 6 L 12 2 D 6 L 20 1 and remove the right shroud 26 PREPARATION ME19001B P A Right Shroud B Bolts D 6 L 12 C Bolt D 6 L 20 e Remove the radiator cap in two steps e First turn the cap counterclockwise to the first stop and wait there for a few seconds e Then push and turn the cap further in the same direction and remove it pal VD05013B G A Radiator Cap Check the coolant level in the radiator The coolant should come up to the bottom of the radiator filler neck NOTE OCheck the coolant level when the engine is cold room or ambient temperature A S VDO5016BM2 C A Coolant Level B Filler Neck elt the coolant level is low add coolant through the radiator filler opening to the bottom of the filler neck e Install the radiator cap and right shroud Transmission Oil Transmission Oil Level Inspection NOTE OThis vehicle s transmission is filled with 10W 40 oil from the factory DO NOT DRAIN and refill the transmission before use Check oil level and drain plug tigh
3. Wiring Band Engine Stop Switch Lead Clutch Cable Route the clutch cable and throttle cable above the front number plate bolt a kh WON Throttle Grip Assembly KX250 R1 Only e Position the throttle grip assembly so that the parting line of the upper and lower throttle cases align with the punched mark on the handlebar and tighten the mounting bolts se curely with the dust cover slipped off e Open and close the throttle grip and check for proper throttle operation Install the dust cover MDO8B040 P A Dust Cover B Throttle Case C Bolt D Punched Mark A WARNING Do not push the throttle grip so far onto the handlebar that the inside of the grip contacts the end of the handlebar This can interfere with throttle action and could result in loss of control Throttle Grip KX250R6F R7F Only e Position the throttle cases with grip assembly so that the parting line of the upper and lower throttle cases horizontally Assembly MDO8032BS1 C A Throttle Case Upper B Throttle Case Lower C Position the Throttle Cases Parting Line Horizontally D Viewed Throttle Cases from Left Side e Tighten the mounting bolts securely with the dust cover slipped off e Open and close the throttle grip and check for proper throttle operation Install dust cover MD08B143 P Dust Cover Throttle Case Upper Throttle Case Lower Bolt Position the Thro
4. Kawasaki KX250 Motorcycle Assembly amp Preparation Manual Foreword In order to ship Kawasaki vehicles as effi ciently as possible they are partially disassem bled before crating Since some of the most commonly removed parts have a direct bear ing on a vehicle s reliability and safety consci entious pre sale assembly and preparation be comes extremely important Good setup pro cedures can prevent needless warranty claims and give customers a greater sense of confi dence in Kawasaki and their Kawasaki Dealers This Assembly and Preparation Manual ex plains step by step procedures of the following items for the Kawasaki KX250 1 Uncrating 2 Assembly 3 Preparation The selling dealer assumes sole responsibil ity for any unauthorized modifications prior to sale Refer to your Service Binder for any Ser vice Bulletins specifying Factory Directed Mod ifications Special Claims which must be per formed before the vehicle is ready for sale Whenever you see the following symbols heed their instructions Always follow safe operating and maintenance practices 2006 Kawasaki Heavy Industries Ltd A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not correctly followed could result in dam a
5. Band Engine Stop Switch Lead Clutch Cable Route the clutch cable and throttle cable above the front number plate bolt a kh WON Handlebar KX250R6F R7F Only e Apply 2 stroke oil on the throttle grip mounting area of the handlebar e Apply a light coat of grease on the exposed portion of the throttle inner cable e Slide the throttle grip dust cover and the grip onto the right hand end of the handlebar MD08B141 P A Throttle Grip B Apply 2 stroke Oil e Set the handlebar on the lower handlebar clamps so that the protrusion of graduation in both sides shall be nearly equal and install the upper handlebar clamps on the handle bar e Apply 2 stroke oil to the threads of the han dlebar clamp bolts D 8 L 35 and install the clamp bolts ASSEMBLY 9 MDO8040BS1 C A Handlebar Clamps Upper B Clamp Bolts C Protrusion C D E Forward F Handlebar MD08052BS1 C A Handlebar Clamp B Align the center of the handlebar clamps with the handlebar bridge C Protrusion C D E Forward Handlebar Clamp Bolt Tightening e Tighten the clamp bolts evenly and tighten them to the specified torque Make sure that there will be even gap on the front and rear side of the clamp after tightening Torque 25 N m 2 5 kgf m 18 ft lb 10 ASSEMBLY MDO8053BS1 C A Forward B Even Gap Viewed from Front MDO8046BS1 C Throttle Cable
6. off for any length of time to avoid moisture contam ination of the fluid Don t add or change brake fluid in the rain or during conditions of blowing dust or debris CAUTION Brake fluid quickly ruins painted sur faces Wipe up any spilled fluid immedi ately e Operate the brake lever several times elt it feels spongy there might be air in the brake line elt necessary bleed the air in the front brake lines e Also check for fluid leakage around the fit tings Front Brake Line Air Bleeding e Remove the reservoir cap and diaphragm and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Attach a clear plastic hose to the bleed valve on the front brake caliper and run the other end of the hose into a container e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the brake master cylinder end of the line e Pump the brake lever a few times until it becomes hard and then holding the lever squeezed quickly open turn counterclock wise and close the bleed valve The
7. or jack to install the front fender and wheel e Discard the crate base e Loosen the right side axle clamp bolt and re move the front axle e The front fender has four inserted collars e Position the front fender between the fork legs and fasten it to the steering stem bracket with four bolts D 6 L 20 A A Front Fender B Bolts D 6 L 20 Front Wheel Assembly KX250 R1 Only Axle Collar NOTE OFit the projection on the cap to the groove on each collar ASSEMBLY 13 A Longer Collar B Caps C Shorter Collar D Apply Grease e Install the longer collar L 29 and cap on the left side of the hub and the shorter collar L 19 and cap on the right side A Axle Clamp Bolts left B Longer Collar left C Cap e Loosely install the front axle clamp bolts D 8 L 40 3 Front Wheel KX250R6F R7F Only Axle Collar Assembly NOTE OFit the projection on the cap to the groove on each collar 14 ASSEMBLY MDOSOO3BS1 C A Collars L 27 5 B Caps C Apply Grease e Fit the axle collars L 27 5 and caps on both sides of the front wheel hub The collars are identical A Axle Clamp Bolts Left B Collar L 27 5 C Cap e Loosely install the front axle clamp bolts D 8 L 40 3 Front Wheel Installation e Put the front wheel assembly between the fork legs e Insert the front brake disc into th
8. screws and remove the top and sides of the crate UNCRATING 3 4 UNCRATING Parts Check e Open the parts box and check the parts against the illustrations There may be mi nor differences between these illustrations and the actual vehicle parts In the following charts under Remarks D diameter in mil limeters and L length in millimeters KX250 R1 O eg L s n e a No Part Name Qty Remarks 1 Handlebar with Grip 1 Handlebar Clamp 1 Clamp Bolt Flanged 4 D 8 L 30 Clamp Master Cylinder 1 Clamp Bolt Master Cylinder 2 D 6 L 22 Clamp Clutch Lever 1 Clamp Bolt with Washer 2 D 5 L 16 Screw Engine Stop Switch 1 D 3 Clamp Engine Stop Switch 2 Wiring Band Engine Stop Switch Lead 1 L 51 6 Fuel Tank Vent Hose with Valve 1 L 370 2 Front Wheel 1 Front Axle Clamp Bolt LH amp RH 3 D 8 L 40 Front Axle Nut 1 D 18 Axle Collar LH 1 L 29 Axle Collar RH 1 L 19 Cap Axle Collar 2 Plastic Front Fender with Collars 1 Flanged Bolt with Washers 4 D 6 L 20 A Front Number Plate 1 Flanged Bolt with Washer Number Plate 1 D 6 L 12 Stand Side 1 Tool Wrench Spark Plug 1 Tool Wrench Spoke Nipple 1 4 Owner s Manual 1 UNCRATING 5 KX250R6F R7F MCO5113BW1 C Stand Side Tool Wrench Spark Plug Tool Wrench Spoke Nipple Remarks Handlebar with Grip 1 RENTHAL Handlebar Clamp 2 Clamp Bolt Flanged 4 D 8 L 35 Handlebar Pad 1 RENTHAL Clamp Master Cyl
9. so that its tab faces upward and its projections align with the holes in the housing and tighten the wing bolt making sure that it is properly seated and sealed To install the seat align the front hook on the seat with front receiver on the fuel tank Slide the seat forward so that center hook engages first followed by the front hook B Front Hook C Front Receiver D Center Hook E Receiver e Fasten the seat mounting bolts left and right Front Brake Fluid Front Brake Fluid Level Inspection e With the front brake fluid reservoir held hori zontal check that the fluid level is above the minimum level line VD18001BM2 C A Front Brake Fluid Reservoir B Minimum Level Line 18 PREPARATION e f the fluid level in the reservoir is below the minimum level line check for fluid leaks in the front brake lines and fill the reservoir e Remove the reservoir cap and diaphragm and fill the reservoir to the maximum level line with DOT4 brake fluid VD18002BM2 C A Front Brake Fluid Reservoir B Maximum Level Line A WARNING Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types of fluid for use in the brakes This lowers the brake fluid boiling point and could reduce brake ef fectiveness It may also cause the rub ber brake parts to deteriorate Don t leave the reservoir cap
10. 0 35 0 50 nuts Use this table for only the bolts and nuts 59 7 8 10 60 0 80 which do not require a specific torque value j j All of the values are for use with dry solvent Wee 19 1 4 1 9 cleaned threads 25 34 2 6 3 5 44 61 4 5 6 2 73 98 7 4 10 0 115 155 11 5 16 0 165 225 17 0 23 0 225 325 23 0 33 0 ft lb 30 43 mb 52 69 in Ib 10 0 13 5 19 0 25 0 33 45 54 72 83 115 125 165 165 240 32 PREPARATION Test Ride the Motorcycle e Complete the test ride check list Control Cables Throttle cable must work without binding in any steering position Steering Action is free from lock to lock Suspension Check operation front and rear Engine Kick starter works properly and engine starts promptly Good throttle response and return Transmission and Clutch Smooth operation Brake Adequate smooth stopping power No drag Engine Stop Switch Works No Unusual Noises No Fuel and Oil Brake Fluid or Coolant Leaks PREPARATION COMPLETE A amp P Check List e Complete the A amp P Check List MODEL APPLICATION Year Model Name 2005 KX250 R1 KX250 2006 KX250R6F KX250 2007 KX250R7F KX250 WE Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99939 1310 04
11. AUTION Do not force to turn the rebound damp ing adjuster from the fully seated posi tion or the adjusting mechanism may be damaged Rebound Damping Settings KX250R6F R7F KR D KX250 R1 x 161514131211109 8 765432 1 Lal tte t ME17010BS1 C A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting Ke Number of turns counterclockwise usable range 16 clicks or more Compression Damping Adjustment KX250 R1 Only e Check the position of the compression damp ing adjuster on the gas reservoir at the upper end of the rear shock absorber STD Compression Damping 12 Clicks Counterclockwise from the fully seated position 24 PREPARATION VD21002BM2 C A Compression Damping Adjuster B Punched Mark C Arrow Mark e To adjust compression damping turn the compression damping adjuster on the gas reservoir with the blade of a screwdriver un til you feel a click Adjust the compression damping to the standard position CAUTION Do not force to turn the compression damping adjuster from the fully seated position or the adjusting mechanism may be damaged Compression Damping Settings oy 16 1514131211109 8 7 6 5 4 3 2 1 d VD21015BM2 C A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwis
12. Inspection e Check that the clutch lever has the specified amount of free play as shown in the figure Clutch Lever Free Play 8 13 mm 0 3 0 5 in NX ON VD12051B G A Clutch Lever B Adjuster with Dust Cover C 8 13 mm 0 3 0 5 in elf the free play is incorrect adjust the free play Clutch Lever Free Play Adjustment e Turn the adjuster so that the clutch lever will have 8 13 mm 0 3 0 5 in of free play e f it cannot be done use the adjuster on the middle of the cable as follows e Turn the adjuster in all the way e Slide the dust cover out of place e Loosen the locknut on the middle upper end of the clutch cable and turn the adjuster so that the clutch lever play is 8 13 mm 0 3 0 5 in A Adjuster B Locknut e Tighten the locknut and slide the dust cover back in place NOTE OAfter the adjustment is made start the engine and check that the clutch does not slip and that it releases properly OFor minor corrections use the adjuster at the clutch lever Drive Chain Drive Chain Slack and Wheel Alignment Inspection e Set the motorcycle up on its side stand e Make sure that the drive chain has the speci fied amount of play and that the left and right notches are on the same marks or points on the left and right of the swingarm A WARNING Misalignment of the wheel will result in abnormal wear and may result in an un safe ridin
13. a a a E A 16 Front Brake Flug 17 Rear Brake Fluid acraea aaie aiee BEER 19 Clutch Lever and Cable ccccccccccccceecceeeeeeeeeeeeeeeeeneeeeeeeneeeeeeees 20 Drive GENEE 20 DOE 21 Rear Shock Abeorber n 23 Tire Air PreSSures cccccccceccceecceecceecceecceecceecceeeeeeceeeeeneseneeeeness 25 NIT 25 COOlAN E AE E A E ET tregatetects seeterctcreceeetancritsautatnates 25 Transmission Oll sre torrare e e aee ea ia a i E 26 Throttle Grip and Cable cccccccccccccceecceecceeeeeeceeeceeeeeeeeeeenees 27 Fastener Check 30 Standard Torque Table 31 Test Ride the Motorcycle 03 s 20 05 ivhetseteretdeachieeeeecavenseveneneenenata ced 32 A amp P Check TSE anerer atie ushered an A EEA 32 Uncrating Opening Crate e Clear a space about 6 m 20 ft square to give yourself plenty of space to work e Place the crate upright on its base e Remove the cardboard cover e Unfasten the bands securing the front wheel assembly to the crate and remove it e Remove the handlebar front wheel and the parts box CAUTION When removing the crate bracket from the motorcycle be careful not to drop any parts or the bracket onto the fuel tank and other components and not to scratch the fuel tank or other compo nents with the crate bracket e Remove the crate bolts D 8 L 14 to take off the crate bracket and discard them A Crate Bolts D 8 L 14 B Crate Bracket e Take out all the bolts and
14. e D Standard Setting K Number of turns counterclockwise usable range 16 clicks or more Compression Damping Adjustment KX250R6F R7F Only There are two adjustments you can make to rear shock absorber gas reservoir e Check the position of the high and low speed compression damping adjusters on the gas reservoir at the upper end of the rear shock absorber STD High Speed Compression Damping 1 1 4 Turns out Counterclockwise from the fully seated position e To adjust the high speed compression damp ing turn the adjuster all the way clockwise with a wrench to make damping greatest e Turn the adjuster counterclockwise to de crease damping Adjust the high speed compression damping to the standard posi tion aes S i ME17B017 P A High Speed Compression Damping Adjuster B Wrench CAUTION Do not force to turn the compression damping adjuster from the fully seated position or the adjusting mechanism may be damaged STD Low Speed Compression Damping 12 Clicks Counterclockwise from the fully seated position e To adjust the low speed compression damp ing turn the adjuster all the way clockwise with a screwdriver to make the damping greatest e Turn the adjuster counterclockwise to de crease damping Adjust the low speed com pression damping to the standard position A Low Speed Compression Damping Adjuster B Screwdriver Low Speed Compression Damping Set ti
15. e front brake pads e Insert the front axle from the right side of the vehicle and install the front axle nut e Tighten the axle nut to the specified torque Front Axle Nut Torque 79 N m 8 0 kgf m 58 ft lb A Front Axle B Collar C Clamp Bolts Right D Front Axle Nut E Clamp Bolts Left F Collar e Gradually tighten the left side axle clamp bolts to the specified torque Front Axle Clamp Bolt Torque 20 N m 2 0 kgf m 14 ft Ib NOTE OTighten the two axle clamp bolts alternately two times to ensure even tightening torque e Before tightening the right side axle clamp bolts pump the front fork up and down 4 or 5 times to align the right front fork leg and to seat the front axle Do not pull the brake lever when pumping the fork NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block in front of the front wheel to stop moving GJ04B229 P A Pump the fork up and down B Block e Gradually tighten the right side axle clamp bolts to the specified torque Front Axle Clamp Bolt Torque 20 N m 2 0 kgf m 14 ft Ib NOTE OTighten the two front axle clamp bolts alter nately two times to ensure even tightening torque A WARNING Do not attempt to ride the motorcycle un til a full brake lever is obtained by pump ing the brake lever until the pads are against the disc The brake will not func tion on the first application of
16. edle Bearing Small End 1 13033 1010 Front Brake Lever 1 13236 0070 Jet Needle NFUG 2 715 1 16187 0163 Wool Muffler L 240 D 31 1 18046 1599 Wool Muffler L 310 D 31 1 18046 1397 Rear Sprocket 51T 1 42041 1451 19 Clutch Lever 1 46092 0007 92033 1336 92055 0049 92055 0050 92055 0052 O Ring Elbow Water Pump 19MM 2 92055 1308 92063 1367 92063 1369 92063 1372 92064 1130 92064 1143 Australian Models Only KX250R7F Models Only 8 ASSEMBLY Assembly Handlebar KX250 R1 Only e Apply 2 stroke oil on the throttle grip mounting area of the handlebar e Apply a light coat of grease on the exposed portion of the throttle inner cable e Slide the throttle grip dust cover and the grip onto the right hand end of the handlebar A Throttle Grip B Apply 2 stroke Oil e Position the handlebar clamp on the handle bar so that the marks of clamp point toward the rear A Handlebar Clamp B Clamp Bolts C Gap D Marks MDO8019BS1 C A Handlebar Clamp B Align the clamp slot with the handlebar bridge c cC D Handlebar Clamp Bolt Tightening e Tighten the front bolts first and then the rear bolts to the specified torque If the handlebar clamp is correctly installed there will be no gap at the front and a gap at the rear after tightening Torque 25 N m 2 5 kgf m 18 ft lb MDO8016BS1 CG Viewed from Front MDO8045BS1 C Throttle Cable Wiring
17. g condition e Raise the rear wheel off the ground rotate the rear wheel to find the place where the chain is tightest because it wears unevenly e Push up the drive chain in the middle of the upper chain run to measure the chain slack The distance between the chain and the swingarm at the end of the chain slipper should be 52 62 mm 2 0 2 5 in Drive Chain Slack 52 62 mm 2 0 2 5 in a Oo ol SOCOC OC YE LIE Ron Sr waa n A 52 62 mm 2 0 2 5 in VD16000BM2 C e Adjust the drive chain if its slack is out of spec ification A WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel se verely damaging the motorcycle and causing it to go out of control Drive Chain Slack Adjustment e Loosen the left and right chain adjuster lock nuts e Remove the cotter pin and loosen the rear axle nut VD16017B G A Rear Axle Nut B Chain Adjusting Bolt C Chain Adjuster Locknut D Marks E Notch F Cotter Pin elt the chain is too loose turn out the left and right chain adjusting bolts evenly elt the chain is too tight turn in the left and right chain adjusting bolts evenly e Turn out both chain adjusting bolts evenly un til the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the chain adjuster notches should align with the same marks in each side of the sw
18. ge to or destruction of equipment NOTE OThis note symbol indicates points of particular interest for more efficient and convenient op eration Kawasaki Heavy Industries Ltd accepts no liability for any inaccuracies or omissions in this publication although every possible measure has been taken to make it as complete and ac curate as possible All procedures and specifi cations subject to change without notice July 2006 Table of Contents UNnCrating Seege GEESS 3 Opening Crate seats ie leis Ee ENEE 3 Parts Check zuer Seen ZENNER ebe oeh AC DEENS A PSSOMIDIY egene dee EEN 8 Handlebar KX250 R1 Only AA 8 Handlebar KX250R6F R7F Only 9 Throttle Grip Assembly KX250 R1 Only 10 Throttle Grip Assembly KX250R6F R7F Only 10 Front Brake Master Cylinder KX250 R1 Only 11 Front Brake Master Cylinder KX250R6F R7F Only 05 11 Clutch Lever Assembly KX250 R1 Only 11 Clutch Lever Assembly KX250R6F R7F Only 12 Engine Stop Switch KX250 R1 Onbhv 12 Engine Stop Switch KX250R6F R7F Only 12 Front ee 12 Front Wheel Assembly KX250 R1 Om 13 Front Wheel Assembly KX250R6F R7F Only 13 Front Wheel Installaton ennenen eenen nnen ne nenene nenene 14 Front Number Plate e ra aa 15 Fuel Tank Vent Hose cccccccceeeeeeeeeceeeeeeeaeeeaaeeaaeaaaeaaaeeaaenaes 15 Side SLANG KEE 16 Brake Kitten deed seed 16 Preparation ENEE ENEE a e AEE E E Aa E AAA EE a TRR 16 AIP CIGANSN gorenen
19. inder 1 Clamp Bolt Master Cylinder 2 D 6 L 22 Clamp Clutch Lever 1 Clamp Bolt with Washer 2 D 5 L 16 Screw Engine Stop Switch 1 D 3 Clamp Engine Stop Switch 2 Wiring Band Engine Stop Switch Lead 1 L 100 Fuel Tank Vent Hose with Valve 1 L 350 Front Wheel 1 Front Axle Clamp Bolt LH amp RH 3 D 8 L 40 Front Axle Nut 1 D 18 Axle Collar LH amp RH 2 L 27 5 Cap Axle Collar 2 Plastic Front Fender with Collars 1 Flanged Bolt with Washer 4 D 6 L 20 Front Number Plate 1 Flanged Bolt with Washer Number Plate 1 D 6 L 12 1 1 1 1 Owner s Manual 6 UNCRATING Spare Parts GO OO O O MCO5152BW4 C e Provide these spare parts to your customer s after none of those incorrect and or defaults were securely reserved These parts and their part numbers are subject to change without prior notice according to the model year UNCRATING 7 No Part Name Part Number 1 Gasket Cylinder Base 2 11061 0091 2 Gasket Cylinder Center Cover 2 11061 0092 3 Gasket Cylinder RH Cover 2 11061 0093 4 Gasket Clutch Outside Cover 2 11061 0095 5 Gasket Water Pump Cover 2 11061 0097 6 Gasket Generator Cover 2 11061 0098 7 Gasket Valve Cover 4 11061 0138 8 Gasket Exhaust Pipe 2 11061 0142 9 Gasket Clutch Inside Cover 2 11061 0144 10 Piston Engine 1 13001 0028 Piston Pin 1 13002 1098 Piston Ring 2 13003 0029 Ne
20. ingarm NOTE OWheel alignment can also be checked using the straightedge or string method e Tighten both chain adjuster locknuts e Tighten the rear axle nut to the specified torque Torque 110 N m 11 0 kgf m 80 ft lb e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary Install a new cotter pin NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise up to the next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past nearest hole PREPARATION 21 IMO7000BS1 C A Cotter Pin B Turning Clockwise e Bend the cotter pin over the nut HJO7002BS1 C A Cotter Pin B Nut A WARNING If the rear axle nut is not securely tight ened or the cotter pin is not installed an unsafe riding condition may result Check the rear brake effectiveness Front Fork Air Pressure Adjustment The standard air pressure in the front fork legs is atmospheric Since the air pressure in the fork legs increases with normal use the fork action stiffens during operation e Raise the front wheel off the ground using a jack special tool e Remove the screw on each front fork top plug to let the air pressure equalize Then reinstall the screws 22 PREPARATION VD20046B G A Screw Compress
21. ion Damping Adjustment e Check the position of the compression damp ing adjusters on the top of the fork tubes STD Compression Damping KX250 R1 10 clicks Counterclockwise from the fully seated position KX250R6F R7F 11 clicks Counterclockwise from the fully seated position VD20045B G A Compression Damping Adjuster e To adjust the compression damping turn the adjuster on each front fork cylinder valve with a flat head screwdriver Adjust the compres sion damping to the standard setting position CAUTION The right and left fork tubes must be ad justed evenly CAUTION Do not force to turn the compression damping adjuster from the fully seated position or the adjusting mechanism may be damaged Compression Damping Settings KX250R6F R7F D D KX250 R1 161514131211109 8 765 4 3 2 1 t ME16036BS1 C A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting Number of turns counterclockwise usable range 16 clicks or more Rebound Damping Adjustment e Check the position of the rebound damping adjusters on the bottom of the fork tubes e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes STD Rebound Damping KX250 R1 12 clicks Counterclockwise from the fully seated position KX250R6F R7F 11 clicks Counterclockwise from the fully seated p
22. knut B Adjuster PREPARATION 29 Dummy Page 30 PREPARATION Fastener Check e The torque values listed are for assembly and preparation items only see the appropriate Service Manual for a more comprehensive list Check tightness of all fasteners that are in the table before retail delivery Also check to see that each cotter pin or circlip is in place PREPARATION 31 No Fastener Torque Remarks N m kgf m ft Ib Steering 1 Handlebar clamp bolts 25 2 5 18 2 Steering stem head nut for KX250 R1 79 8 0 58 Steering stem head nut for KX250R6F R7F 98 10 0 72 Brake Front master cylinder clamp bolts 8 8 0 90 78 mb S Front caliper mounting bolts 25 2 5 18 Front brake bleed valve 7 8 0 80 69 in Ib 10 Tse 0 80 eet Wheel 8 Frontaxlenut 8 amp 0 s 14 AL Suspension S um a 11 Rear shock absorber mounting nut Upper 29 25 13 Swingarm protshatnt Jm w z e Transmission Oil Drain Plug 14 Cotter Pin or Circlip 16 Rear axe nut schen ll 17 Rear master oylinder coter J 18 Footpeg cotter pins Left and Right AL Tighten the two clamp bolts alternately two times to ensure even tightening torque S Tighten the upper clamp bolt first and then the lower clamp bolt General Fasteners Standard Torque Table Threads Torque This table relating tightening torque to thread dia mm N m kgf m diameter lists the basic torque for bolts and 34 4 9 1
23. lamps align with the punched mark on the handlebar e Tighten the clamp bolts 12 ASSEMBLY A Clutch Lever Assy and Dust Cover B Bolt D 5 L 16 C Punched Mark Clutch Lever KX250R6F R7F Only Assembly e Install the clutch lever with the clamp and bolts D 5 L 16 on the handlebar as shown e Tighten the clamp bolts MDO8031BS1 C A Clutch Lever Assy B 180 mm 7 1 in C Bolts D 5 L 16 D Horizontal Line E 20 5 Engine Stop Switch KX250 R1 Only Install the engine stop switch and its clamps between the grip and the clutch lever with the small screw and tighten it A Engine Stop Switch B Clamps C Screw D Wiring Band e Fix the engine stop switch lead to the handle bar with the wiring band L 51 6 Engine Stop Switch KX250R6F R7F Only Install the engine stop switch and its clamps between the grip and the clutch lever with the small screw and tighten it A Engine Stop Switch B Clamps C Screw D Wiring Band L 100 e Fix the engine stop switch lead to the handle bar with the wiring band L 100 Front Fender e Remove the crate bolts D 8 L 30 to take off the crate bracket and discard them MCO3B024 P A Crate Bolts D 8 L 30 B Crate Bracket C Clamp Bolt Right D Front Axle o Lift the motorcycle off the crate base and sup port the motorcycle with a suitable stand
24. m and check that there is plenty of fluid in the reservoir PREPARATION 19 NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line e Attach a clear plastic hose to the bleed valve on the rear brake caliper and run the other end of the hose into a container e With the reservoir cap off slowly pump the brake pedal several times until no air bub bles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the rear brake master cylinder end of the line e Pump the brake pedal a few times until it becomes hard push the pedal and hold then quickly open turn counterclockwise and close the bleed valve Release the pedal Repeat this operation until no more air can MEO7B054 P A Hold the brake pedal applied B Quickly open and close the bleed valve C Release the brake pedal e When air bleeding is finished check the fluid level e Install the diaphragm and reservoir cap e Tighten the bleed valve to the specified torque Torque 7 8 N m 0 80 kgf m 69 in Ib e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings 20 PREPARATION Clutch Lever and Cable Clutch Lever Free Play
25. n release the lever Repeat this operation until no more air can be seen coming out into the plastic hose A Hold the brake lever applied B Quickly open and close the bleed valve C Release the brake lever e When air bleeding is finished check that the fluid level is between the maximum and mini mum level lines e Install the diaphragm and reservoir cap e Tighten the bleed valve to the specified torque Torque 7 8 N m 0 80 kgf m 69 in Ib e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Rear Brake Fluid Rear Brake Fluid Level Inspection e With the rear brake fluid reservoir positioned horizontally check that the fluid level is above the minimum level line VD18010BM2 C A Rear Brake Fluid Reservoir B Minimum Level Line e f the fluid level in the reservoir is below the minimum level line check for fluid leaks in the rear brake lines and fill the reservoir e Remove the reservoir cap and diaphragm and fill the reservoir to the maximum level line with DOT4 brake fluid VD18011BM2 C A Rear Brake Fluid Reservoir B Maximum Level Line e Operate the brake pedal several times elt it feels spongy there might be air in the brake line elt necessary bleed the air in the rear brake lines e Also check for fluid leakage around the fit tings Rear Brake Line Air Bleeding e Remove the reservoir cap and diaphrag
26. ngs 16 1514131211109 8 7 6 5 43 2 1 d VD21015BM2 C A Seated Position Adjuster Turn Fully Clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting K Number of turns counterclockwise usable range 16 clicks or more Tire Air Pressures e To prevent flat spotting during shipment the tires are over inflated before crating Adjust the pressures to the specified values in the front and rear and make sure to tighten the caps securely Tire Air Pressure when cold Front 80 100 kPa 0 8 1 0 kgficm 11 14 psi Rear 80 100 kPa 0 8 1 0 kgf cm 11 14 psi PREPARATION 25 Fuel A WARNING Fill the tank in a well ventilated area and take ample care that there are no sparks or open flames anywhere near the work area e Fill the fuel tank with one gallon of unleaded gasoline oil mixture 32 1 The oil must be a good quality two stroke racing oil e Use a gasoline with a minimum antiknock in dex rating in accordance with the regulations of your country Refer to the following table The antiknock index is an average of the Re search Octane Number RON and the Motor Octane Number MON as shown in the table Octane Rating Method EE Rating Antiknock RON MON 90 Index 2 Research Octane Number RON 95 e Close the fuel tank cap Turn the fuel tap lever a few times and check for any leaks Coolant NOTE
27. osition VD20021BM2 C A Rebound Damping Adjuster e To adjust the rebound damping turn the ad juster on each front fork tubes with a flat head screwdriver Adjust the rebound damping to the standard setting position CAUTION The right and left fork tubes must be ad justed evenly CAUTION Do not force to turn the rebound damp ing adjuster from the fully seated posi tion or the adjusting mechanism may be damaged Rebound Damping Settings KX250 R1 RON KX250R6F R7F 161514131211109 8 7 6543 2 1 t ME16037BS1 C A Seated Position Adjuster turned fully clockwise B Softer Counterclockwise C Harder Clockwise D Standard Setting Ke Number of turns counterclockwise usable range 16 clicks or more e Install the caps on the bottom of the fork tubes Rear Shock Absorber Rebound Damping Adjustment e Check the position of the rebound damping adjuster at the bottom of the rear shock ab sorber STD Rebound Damping KX250 R1 9 Clicks Counterclockwise from the fully seated position KX250R6F R7F 10 Clicks Counterclockwise from the fully seated position PREPARATION 23 VD21012B G A Rebound Damping Adjuster e To adjust the rear shock absorber rebound damping turn the rebound damping adjuster at the bottom of the rear shock absorber with a flat head screwdriver Adjust the rebound damping to the standard setting position C
28. t the throttle grip free play If the free play is incorrect adjust the throttle cable Throttle Grip Free Play 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering posi tions by the return spring If the throttle grip does not return properly check the throttle ca ble routing grip free play and for possible ca ble damage Then lubricate the throttle cable VD10000BM2 C A Adjuster B Locknut C Throttle Grip D 2 3 mm 0 08 0 12 in e Run the engine at idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change If the idle speed increases check the throttle grip free play and the cable routing A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condi tion Throttle Grip Free Play Adjustment e Slide the cable adjuster dust cover out of place e Loosen the locknut at the throttle grip and turn the adjuster until the specified amount of play is obtained e Tighten the locknut and slide the dust cover back in place 28 PREPARATION NOTE Olf the proper throttle grip free play cannot be adjusted at the throttle grip or the middle of the cable use the adjuster at the carburetor Do not forget to securely tighten the locknut VD10001BM2 C A Loc
29. the lever if this is not done Front Number Plate e Position the front number plate between the brake hose and the front fork and fit the two projections on the number plate into the holes in the steering stem bracket MD12B008 E A Front Number Plate B Projection C Hole e Route the clutch cable and throttle cable above the front number plate bolt as show e Fasten the number plate to the stem head with the flanged bolt D 6 L 12 and attach the belt to the handlebar bridge and latch the belt ASSEMBLY 15 A Front Number Plate B Bolt D 6 L 12 C Clutch Cable D Throttle Cable Handlebar Pad Installation KX250R6F R7F Only e Before attach the belt install the handlebar pad onto the handlebar bridge as shown A Handlebar Pad e Attach the number plate belt to the handlebar pad and latch the belt Fuel Tank Vent Hose e Fit the shorter hose end of the vent hose into the fuel tank cap making sure the arrow on the valve points toward the cap 16 PREPARATION A Vent Hose B Arrow e Fit the other end into the hole of the steering stem shaft Side Stand Usage e Fit the flat bar end of the side stand into the rear axle shaft D A Side Stand NOTE ODo not start the engine or attempt to ride the motorcycle when the side stand is installed Brake Disc Cleaning e Clean the front and rear brake discs using oilless solvent
30. tness Transmission Oil Drain Plug Torque 20 N m 2 0 kgf m 14 ft Ib a er G117002BS1 C A Transmission Oil Drain Plug e Park the vehicle so that it is level both side to side and front to rear e Before starting the engine verify that the transmission has oil eWith the motorcycle perpendicular to the ground check the transmission oil level through the oil level sight gauge on the lower right side of the engine The oil should come up to the center of the oil level gauge em VD03005B G A Oil Level Sight Gauge B Maximum C Minimum D Oil Filler Cap e f the oil level is too high remove the excess oil using a syringe or other suitable device elt the oil level is low add the correct amount of oil through the oil filler opening CAUTION If the engine is run without oil it will be severely damaged Recommended Transmission Oil Type API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 0 85 L 0 90 US qt Although 10W 40 transmission oil is the rec ommended oil for most conditions the oil vis cosity may need to be changed to accommo date atmospheric conditions in your riding area SAE 10W 50 SAE 10W 40 ss Be ee ey SAE 10W 30 20 10 0 10 20 30 40 L 4 14 32 50 68 86 104 F Lk VDO4000BM2 C PREPARATION 27 Throttle Grip and Cable Throttle Grip Free Play Inspection e Inspec
31. ttle Cases Parting Line Horizontally Viewed Throttle Cases from Left Side Dm Dom gt 7 A WARNING Do not push the throttle grip so far onto the handlebar that the inside of the grip contacts the end of the handlebar This can interfere with throttle action and could result in loss of control Front Brake Master Cylinder KX250 R1 Only Install the master cylinder with the clamps on the handlebar e Position the master cylinder so that the ver tical parting line of the front and rear master cylinder clamps align with the punched mark on the handlebar A Bolt Upper B UP Mark C Punched Mark ASSEMBLY 11 e Tighten the upper clamp bolt first and then the lower bolt to the specified torque Torque 8 8 N m 0 90 kgf m 78 in Ib Front Brake Master Cylinder KX250R6F R7F Only e Install the master cylinder with the clamp and bolts D 6 L 22 on the handlebar so that the master cylinder horizontally MDO8033BS1 C A Front Brake Master Cylinder B 185 mm 7 3 in C Horizontal Line e Tighten the upper clamp bolt first and then the lower bolt to the specified torque Torque 8 8 N m 0 90 kgf m 78 in Ib MD08B144 P A Bolts D 6 L 22 B UP Mark Clutch Lever Assembly KX250 R1 Only e Install the clutch lever with the clamps and bolts D 5 L 16 on the handlebar so that the vertical parting line of the front and rear clutch lever c
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