KX250F (2013-2015)

KX250F
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Clutch 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
Crankshaft/Transmission 9 j
Wheels/Tires 10 j
Final Drive 11 j
Brakes 12 j
Suspension 13 j
Steering 14 j
Frame 15 j
Electrical System 16 j
This quick reference guide will assist

Appendix 17 j
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
KX250F
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2012 Kawasaki Heavy Industries, Ltd. 3rd Edition (0) : Mar. 17, 2014
LIST OF ABBREVIATIONS
A ampere(s) KDS Kawasaki Diagnostic System
ABDC after bottom dead center km/h kilometers per hour
AC alternating current L liter(s)
Ah ampere hour lb pound(s)
ATDC after top dead center LED Light Emitting Diode
BBDC before bottom dead center m meter(s)
BDC bottom dead center min minute(s)
BTDC before top dead center mph miles per hour
°C degree(s) Celsius N newton(s)
cmHg centimeters of mercury oz ounce(s)
cu in cubic inch(s) Pa pascal(s)
DC direct current PS horsepower
DFI Digital Fuel Injection psi pound(s) per square inch
ECU Electronic Control Unit qt quart(s)
F farad(s) r revolution
°F degree(s) Fahrenheit rpm revolution(s) perminute
ft foot, feet s second(s)
g gram(s) TDC top dead center
gal gallon(s) TIR total indicator reading
h hour(s) V volt(s)
HP horsepower(s) W watt(s)
in. inch(s) Ω ohm(s)
COUNTRY AND AREA CODES

AU Australia EUR Europe
BR Brazil TH Thailand
CA Canada US United States
Foreword
This manual is designed primarily for use by For example, if you want stick coil information,
trained mechanics in a properly equipped shop. use the Quick Reference Guide to locate the
However, it contains enough detail and basic in- Electrical System chapter. Then, use the Table
formation to make it useful to the owner who de- of Contents on the first page of the chapter to
sires to perform his own basic maintenance and find the Stick Coil section.
repair work. A basic knowledge of mechanics, Whenever you see symbols, heed their in-
the proper use of tools, and workshop proce- structions! Always follow safe operating and
dures must be understood in order to carry out maintenance practices.
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or DANGER
doubts his ability to do the work, all adjust- DANGER indicates a hazardous situa-
ments, maintenance, and repair should be car- tion which, if not avoided, will result in
ried out only by qualified mechanics. death or serious injury.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor- WARNING
oughly familiarize yourself with the procedures WARNING indicates a hazardous situa-
before starting work, and then do the work care- tion which, if not avoided, could result
fully in a clean area. Whenever special tools or in death or serious injury.
equipment are specified, do not use makeshift
tools or equipment. Precision measurements NOTICE
can only be made if the proper instruments are
used, and the use of substitute tools may ad- NOTICE is used to address practices not
versely affect safe operation. related to personal injury.
To get the longest life out of your vehicle: This manual contains four more symbols
• Follow the Periodic Maintenance Chart in the
Service Manual.
which will help you distinguish different types
of information.
• Be alert for problems and non-scheduled
maintenance. NOTE
• Use proper tools and genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
○NOTE indicates information that may help
or guide you in the operation or service of
testers that are necessary when servicing the vehicle.
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as • Indicates
done.
a procedural step or work to be
spare parts are listed in the Parts Catalog.
• Follow the procedures in this manual care- ○Indicates a procedural sub-step or how to do
fully. Don’t take shortcuts. the work of the procedural step it follows. It
• Remember to keep complete records of main-
tenance and repair with dates and any new
also precedes the text of a NOTE.
Indicates a conditional step or what action to
parts installed. take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
How to Use This Manual In most chapters an exploded view illustration
In this manual, the product is divided into of the system components follows the Table of
its major systems and these systems make up Contents. In these illustrations you will find the
the manual’s chapters. The Quick Reference instructions indicating which parts require spec-
Guide shows you all of the product’s system ified tightening torque, oil, grease or a locking
and assists in locating their chapters. Each agent during assembly.
chapter in turn has its own comprehensive Ta-
ble of Contents.
GENERAL INFORMATION 1-1
General Information
Table of Contents
1
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Unit Conversion Table ............................................................................................................ 1-11
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High
flash-point solvent should be used according to directions
of the solvent manufacturer.
Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Before Servicing
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled. If
there is a different replacement instruction in any other part
of this manual for the specific part, follow it.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Before Servicing
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.
All of the tightening torque values are for use with dry,
solvent - cleaned threads unless otherwise indicated. If a
fastener which should have dry, clean threads gets contami-
nated with lubricant, etc., applying even the specified torque
could damage it.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling.
Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Before Servicing
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing

the seal.
Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in-
stalling to prevent deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Before Servicing
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Leads
A two-color lead is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
leads must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
Model Identification
KX250ZD Left Side View
KX250ZD Right Side View
Frame Number Engine Number

General Specifications
Items KX250ZD ∼ ZF
Dimensions
Overall Length 2 170 mm (85.43 in.)
Overall Width 820 mm (32.3 in.)
Overall Height 1 270 mm (50.00 in.)
Wheelbase 1 475 mm (58.07 in.)
Road Clearance 330 mm (13.0 in.)
Seat Height 945 mm (37.2 in.)
Curb Mass: 106.2 kg (234.2 lb)
(US, CA) 106.0 kg (233.7 lb)
Front: 51.7 kg (114.0 lb)
Rear: 54.5 kg (120.2 lb)
(US, CA) 54.3 kg (119.7 lb)
Fuel Tank Capacity 6.1 L (1.6 US gal)
Engine
Type 4-stroke, single cylinder, DOHC 4 valve
Cooling System Liquid-cooled
Bore and Stroke 77.0 × 53.6 mm (3.03 × 2.11 in.)
Displacement 249 cm³ (15.2 cu in.)
Compression Ratio 13.8:1
Fuel System FI (Fuel Injection), KEIHIN 43
Fuel Type:
Minimum Octane Rating:
Research Octane Number (RON) (AU, EUR, TH) 95
Antiknock Index (RON + MON)/2 (US, CA, BR) 90
Starting System Primary kick
Ignition System Digital DC-CDI
Timing Advance Electronically advanced
Ignition Timing BTDC 4° @2 000 r/min (rpm)
Spark Plug:
Standard: NGK CPR8EB-9
Terminal Solid post
Option: NGK CPR9EB-9
Terminal Solid post
Valve Timing:
Intake:
Open BTDC 36°
Close ABDC 76°
Duration 292°
Exhaust:
Open BBDC 69°
Close ATDC 49°
Duration 298°
Lubrication System Forced lubrication (semi-dry sump)
Engine Oil:
Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or
MA2
Viscosity SAE 10W-40
Capacity 1.0 L (1.1 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 3.350 (67/20)
Clutch Type Wet multi disc, Manual
Transmission:
Type 5-speed, constant mesh, return shift
Gear Ratios:
1st 2.142 (30/14)
2nd 1.750 (28/16)
3rd 1.444 (26/18)
4th 1.235 (21/17)
5th 1.045 (23/22)
Final Drive System:
Type Chain drive
Reduction Ratio 3.846 (50/13)
Overall Drive Ratio 13.470 at Top gear
Frame
Type Tubular, semi-double cradle
Steering Angle 42° to either side
Caster (Rake Angle) 28.7°
Trail 126.4 mm (4.976 in.)
Front Wheel:
Tire Size 80/100-21 51M
Tire Make/Type DUNLOP MX51FA, Tube type
Rim Size 21 × 1.60
Rear Wheel:
Tire Size 100/90-19 57M
Tire Make/Type DUNLOP MX51, Tube type
Rim Size 19 × 1.85
Front Suspension:
Type Telescopic fork (upside down)
Wheel Travel 315 mm (12.4 in.)
Rear Suspension:
Type Swingarm (New Uni-trak)
Wheel Travel 310 mm (12.2 in.)
Brake Type:
Front and Rear Single disc
Effective Disc Diameter:
Front 225 mm (8.86 in.)
Rear 215 mm (8.46 in.)
Specifications are subject to change without notice, and may not apply to every country.
Unit Conversion Table
Prefixes for Units: Units of Length:
km × 0.6214 = mile
Prefix Symbol Power
m × 3.281 = ft
mega M × 1 000 000
mm × 0.03937 = in.
kilo k × 1 000
centi c × 0.01
milli m × 0.001 Units of Torque:
micro µ × 0.000001 N·m × 0.1020 = kgf·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
Units of Mass: kgf·m × 9.807 = N·m
kg × 2.205 = lb kgf·m × 7.233 = ft·lb
g × 0.03527 = oz kgf·m × 86.80 = in·lb
Units of Volume: Units of Pressure:

L × 0.2642 = gal (US) kPa × 0.01020 = kgf/cm²
L × 0.2200 = gal (IMP) kPa × 0.1450 = psi
L × 1.057 = qt (US) kPa × 0.7501 = cmHg
L × 0.8799 = qt (IMP) kgf/cm² × 98.07 = kPa
L × 2.113 = pint (US) kgf/cm² × 14.22 = psi
L × 1.816 = pint (IMP) cmHg × 1.333 = kPa
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (IMP) Units of Speed:
mL × 0.06102 = cu in. km/h × 0.6214 = mph
Units of Force: Units of Power:

N × 0.1020 = kg kW × 1.360 = PS
N × 0.2248 = lb kW × 1.341 = HP
kg × 9.807 = N PS × 0.7355 = kW
kg × 2.205 = lb PS × 0.9863 = HP
Units of Temperature:
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-3
Torque and Locking Agent...................................................................................................... 2-5 2
Specifications ......................................................................................................................... 2-9
Special Tools .......................................................................................................................... 2-12
Periodic Maintenance Procedures.......................................................................................... 2-14
Fuel System (DFI)................................................................................................................ 2-14
Fuel Hose and Connections Inspection ............................................................................ 2-14
Throttle Grip (Throttle Cable) Free Play Inspection .......................................................... 2-14
Throttle Grip (Throttle Cable) Free Play Adjustment......................................................... 2-14
Throttle Body Cleaning ..................................................................................................... 2-15
Fuel Hose Replacement ................................................................................................... 2-15
Idle Speed Inspection ....................................................................................................... 2-18
Idle Speed Adjustment...................................................................................................... 2-19
Air Cleaner Element Cleaning and Inspection .................................................................. 2-19
Fuel Tank Cleaning ........................................................................................................... 2-21
Cooling System.................................................................................................................... 2-21
Coolant Level Inspection................................................................................................... 2-22
Coolant Deterioration Inspection....................................................................................... 2-23
Water Hoses and Connections Inspection ........................................................................ 2-23
Engine Top End ................................................................................................................... 2-23
Valve Clearance Inspection .............................................................................................. 2-23
Valve Clearance Adjustment............................................................................................. 2-24
Cylinder Head Warp Inspection ........................................................................................ 2-26
Cylinder Wear Inspection.................................................................................................. 2-26
Piston/Cylinder Clearance Inspection ............................................................................... 2-27
Piston, Piston Ring and Piston Pin Replacement ............................................................. 2-27
Exhaust System Inspection............................................................................................... 2-27
Silencer Wool Replacement.............................................................................................. 2-28
Clutch................................................................................................................................... 2-29
Clutch Operation Inspection.............................................................................................. 2-29
Clutch Plates Inspection ................................................................................................... 2-29
Engine Lubrication System .................................................................................................. 2-30
Engine Oil Change............................................................................................................ 2-30
Oil Filter Change ............................................................................................................... 2-31
Breather Hose Inspection ................................................................................................. 2-32
Crankshaft/Transmission ..................................................................................................... 2-33
Crankshaft Inspection ....................................................................................................... 2-33
Wheels/Tires ........................................................................................................................ 2-33
Air Pressure Inspection/Adjustment.................................................................................. 2-33
Tires Inspection................................................................................................................. 2-34
Spoke Tightness Inspection .............................................................................................. 2-34
Rim Runout Inspection...................................................................................................... 2-34
Wheel Bearing Inspection ................................................................................................. 2-35
Final Drive............................................................................................................................ 2-35
Drive Chain Wear Inspection ............................................................................................ 2-35
Drive Chain Slack Inspection ............................................................................................ 2-36
Rear Axle Nut Inspection (KX250ZF)................................................................................ 2-37
Drive Chain Slack Adjustment .......................................................................................... 2-37
Drive Chain Lubrication..................................................................................................... 2-38
Sprocket Wear Inspection................................................................................................. 2-38
2-2 PERIODIC MAINTENANCE
Rear Sprocket Warp (Runout) Inspection ......................................................................... 2-39

Brakes.................................................................................................................................. 2-40
Brake Lever and Pedal Adjustment .................................................................................. 2-40
Brake Fluid Level Inspection............................................................................................. 2-41
Brake Fluid Change .......................................................................................................... 2-42
Brake Pad Wear Inspection .............................................................................................. 2-44
Brake Master Cylinder Rubber Parts Replacement .......................................................... 2-44
Caliper Rubber Parts Replacement .................................................................................. 2-46
Brake Hoses and Connections Inspection ........................................................................ 2-49
Brake Hose Replacement ................................................................................................. 2-49
Suspension .......................................................................................................................... 2-51
Front Fork Inspection ........................................................................................................ 2-51
Front Fork Oil Change ...................................................................................................... 2-51
Rear Shock Absorber Oil Change..................................................................................... 2-72
Swingarm and Uni-Trak Linkage Inspection ..................................................................... 2-80
Swingarm and Uni-Trak Linkage Pivot Lubrication ........................................................... 2-80
Steering ............................................................................................................................... 2-81
Steering Inspection ........................................................................................................... 2-81
Steering Adjustment ......................................................................................................... 2-81
Steering Stem Bearing Lubrication ................................................................................... 2-82
Frame .................................................................................................................................. 2-83
Frame Inspection .............................................................................................................. 2-83
Electrical System ................................................................................................................. 2-83
Spark Plug Cleaning and Inspection................................................................................. 2-83
Spark Plug Replacement .................................................................................................. 2-83
General Lubrication and Cable Inspection........................................................................... 2-84
Lubrication ........................................................................................................................ 2-84
Cable Inspection ............................................................................................................... 2-85
Nut, Bolt, and Fastener Tightness Inspection...................................................................... 2-85
Tightness Inspection ......................................................................................................... 2-85
Periodic Maintenance Chart
The maintenance must be done in accordance with this chart to keep the motorcycle in good running
condition.
FREQUENCY Each Every Every 6
Every 12
race 3 races races See
races or
or 2.5 or 7.5 or 15 Page
30 hours
OPERATION hours hours hours
Spark plug - clean and inspect † • 2-83
Spark plug - replace • 2-83
Clutch - inspect • 2-29
Clutch plates - inspect † • 2-29
Throttle cable - inspect and adjust • 2-14
Air cleaner element - clean • 2-19
Air cleaner element - replace If damaged 2-19
Throttle body assy - inspect and adjust • 2-15
Engine oil - change • 2-30
E
N
Piston and piston ring - replace • 2-27
G Cylinder head, cylinder - inspect • 2-26
I
N
Piston pin - replace • 2-27
E
Valve clearance - inspect † • 2-23
Oil filter - replace • 2-31
Exhaust system - inspect † • 2-27
Silencer wool - change • 2-28
Kick pedal and shift pedal - clean • –
Engine sprocket - inspect † • 2-38
Coolant level - inspect • 2-22
Water hoses and connections - inspect † • 2-23
Crankshaft - inspect • 2-33
Breather hose - inspect • 2-32
Brake - adjust † • 2-40
Brake pad wear - inspect † • 2-44
Brake fluid level - inspect † • 2-41
Brake fluid - change Every 2 years 2-42
C Brake master cylinder cup and dust cover - replace Every 2 years 2-44
H Brake caliper fluid seal and dust seal - replace Every 2 years 2-46
A Brake hoses - replace Every 4 years 2-49
S Brake hoses, connections - inspect †
S • 2-49
I Spoke tightness and rim runout - inspect † • 2-34
S Wheel bearing - inspect †
• 2-35
Frame - inspect • 2-83
Rear axle nut - inspect (KX250ZF) † • 2-37
Drive chain wear - inspect † • 2-35
Drive chain - inspect and adjust • 2-36
Periodic Maintenance Chart
FREQUENCY Each Every Every 6

Every 12
race 3 races races See
races or
or 2.5 or 7.5 or 15 Page
30 hours
OPERATION hours hours hours
Drive chain - lubricate • 2-38
Wheels/tires - inspect • 2-34
Rear sprocket - inspect † • 2-39
Front fork - clean and inspect • 2-51
Front fork oil - change • 2-51
C
Rear shock absorber oil - change • 2-72
H
Cable - inspect • 2-85
A Fuel hose - replace Every 5 years 2-15
S
S
Fuel hose, connections - inspect † • 2-14
I
Fuel system - clean • 2-21
S Steering play - inspect † • 2-81
Steering stem bearing - lubricate • 2-82
Swingarm and Uni-Trak linkage pivots - lubricate • 2-80
Swingarm and Uni-Trak linkage pivots - inspect † • 2-80
Nuts, bolts, fasteners - inspect † • 2-85
General lubrication - perform • 2-84
†: Replace, add, adjust, clean or torque if necessary.
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The
following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of
a non-permanent locking agent or silicone grease etc. All of the values are for use with dry solvent -
cleaned threads unless otherwise indicated.
When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten to specified torque.
Letters used in the “Remarks” column mean:
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
G: Apply grease.
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
T: First, tighten the stem nut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and retighten
it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.
2T: Apply 2-stroke oil.
Torque
Fastener Remarks
N·m kgf·m ft·lb
Fuel System (DFI)
Throttle Pulley Cover Bolts 3.4 0.35 30 in·lb
Throttle Cable Bolts 3.0 0.31 27 in·lb
Air Cleaner Duct Clamp Bolt 2.0 0.20 18 in·lb
Throttle Case Mounting Screws 3.8 0.39 34 in·lb
Delivery Joint Bolt 3.5 0.36 31 in·lb L
Water Temperature Sensor 12 1.2 106 in·lb
Gear Position Switch Screws 2.9 0.30 26 in·lb L
Cooling System
Water Hose Clamp Screws 3.0 0.31 27 in·lb
Water Pipe Bolt 9.8 1.0 87 in·lb
Water Pump Cover Bolts (L = 55 mm) 9.8 1.0 87 in·lb L
Water Pump Impeller Bolt 7.0 0.71 62 in·lb
Water Pump Cover Bolts (L = 30, 65 mm) 9.8 1.0 87 in·lb
Coolant Drain Bolt 7.0 0.71 62 in·lb
Engine Top End
Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
Camshaft Cap Bolts 9.8 1.0 87 in·lb MO, S
Plug 20 2.0 15 L
Cylinder Head Bolts (M10) 44 4.5 32 MO, R, S
Auto-Decompressor Bolt 12 1.2 106 in·lb
Cylinder Head Bolts (M6) 12 1.2 106 in·lb S
Cylinder Bolt 12 1.2 106 in·lb S
Throttle Body Assy Clamp Screw 2.0 0.20 18 in·lb
Throttle Body Assy Holder Clamp Screw 2.0 0.20 18 in·lb
Lower Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb
Torque
Fastener Remarks
N·m kgf·m ft·lb
Rear Camshaft Chain Guide Bolt 15 1.5 11
Camshaft Chain Tensioner Cap Bolt 20 2.0 15
Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb
Clutch
Right Engine Cover Bolts 9.8 1.0 87 in·lb
Clutch Cover Bolts 9.8 1.0 87 in·lb
Oil Filler Plug 3.5 0.36 31 in·lb
Clutch Hub Nut 98 10.0 72 R
Clutch Spring Bolts 9.0 0.92 80 in·lb
Engine Lubrication System
Oil Filter Cap Bolts 9.8 1.0 87 in·lb
Piston Oil Nozzle 2.9 0.30 26 in·lb
Breather Fitting 15 1.5 11
Oil Pump Idle Gear Shaft Screws 5.9 0.60 52 in·lb L
Oil Pump Mounting Bolts 7.0 0.71 62 in·lb L
Engine Oil Drain Bolt 20 2.0 15
Engine Removal/Installation
Upper Engine Mounting Bolts 49 5.0 36 S
Upper Engine Bracket Bolts 29 3.0 21 S
Middle Engine Bracket Nuts 29 3.0 21 R, S
Middle Engine Mounting Nut 49 5.0 36 R, S
Lower Engine Mounting Nut 49 5.0 36 R, S
Swingarm Pivot Shaft Nut 98 10.0 72 R, S
Crankshaft/Transmission
Primary Gear Nut 98 10.0 72 Lh, R
Reed Valve Screws 7.0 0.71 62 in·lb
Crankcase Bearing Retainer Screws 15 1.5 11 L
Piston Oil Nozzle 2.9 0.30 26 in·lb
Crankcase Bolts (L = 50 mm) 9.8 1.0 87 in·lb S
Crankcase Bolt (L = 65 mm) 9.8 1.0 87 in·lb S
Kick Ratchet Guide Bolt 8.8 0.90 78 in·lb L
Kick Pedal Bolt 25 2.5 18 L
Shift Drum Cam Bolt 24 2.4 18 L
Gear Positioning Lever Nut 8.8 0.90 78 in·lb
Ratchet Plate Bolt 9.8 1.0 87 in·lb L, S
Ratchet Plate Screw 15 1.5 11 L, S
Shift Pedal Bolt 9.8 1.0 87 in·lb
Wheels/Tires
Spoke Nipples Not less Not less than Not less than
than 2.2 0.22 19 in·lb
Front Axle Nut 78 8.0 58
Torque
Fastener Remarks
N·m kgf·m ft·lb
Front Axle Clamp Bolts (KX250ZD ∼ ZE) 20 2.0 15 AL, S
Front Axle Clamp Bolts (KX250ZF) 23 2.3 17 AL, S
Rear Axle Nut (KX250ZD ∼ ZE) 108 11.0 79.7
Rear Axle Nut (KX250ZF) 108 11.0 79.7 R
Final Drive
Rear Sprocket Nuts 34 3.5 25 R
Engine Sprocket Nut (KX250ZE ∼) 78 8.0 57
Brakes
Brake Hose Banjo Bolts 25 2.5 18
Front Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si
Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
Front Brake Disc Mounting Bolts 9.8 1.0 87 in·lb L
Front Brake Pad Pin 17 1.7 13
Caliper Bleed Valves 7.8 0.80 69 in·lb
Front Caliper Mounting Bolts 25 2.5 18
Rear Brake Reservoir Cap Bolts 1.5 0.15 13 in·lb
Rear Master Cylinder Mounting Bolts 9.8 1.0 87 in·lb
Rear Master Cylinder Push Rod Locknut 17 1.7 13
Brake Pedal Bolt 25 2.5 18 G, L
Rear Caliper Holder Shaft 27 2.8 20 Si
Rear Brake Pad Pin 17 1.7 13
Rear Brake Pad Pin Plug 2.4 0.24 21 in·lb
Rear Brake Disc Mounting Bolts 23 2.3 17 L
Suspension
Air Pressure Relief Screws 1.3 0.13 12 in·lb
Left Front Fork Base Valve Assembly 30 3.1 22
Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L
Front Fork Clamp Bolts (Lower) 22 2.2 16 AL
Right Front Fork Spring Adjuster Unit 34 3.5 25
Left Front Fork Cylinder Unit 34 3.5 25
Left Front Fork Adjuster Assembly Locknut 22 2.2 16
Left Front Fork Adjuster Assembly 69 7.0 51 L
Right Front Fork Spring Preload Adjuster 30 3.1 22
Right Front Fork Bottom Plug Locknut 22 2.2 16
Right Front Fork Bottom Plug 69 7.0 51 L
Rear Shock Absorber Mounting Nut 39 4.0 29 R
(Upper)
Rear Shock Absorber Mounting Nut 34 3.5 25 R
(Lower)
Tie-Rod Mounting Nuts 59 6.0 44 R
Swingarm Pivot Shaft Nut 98 10.0 72 R
Torque
Fastener Remarks
N·m kgf·m ft·lb
Rocker Arm Pivot Nut 59 6.0 44 R
Gas Reservoir Damping Adjuster 29.5 3.01 21.8
Assembly
Rear Shock Absorber Spring Locknut 45 4.6 33
Piston Rod Locknut 37 3.8 27 R
Steering
Handlebar Clamp Bolts 25 2.5 18 AL, 2T
Steering Stem Head Nut 98 10.0 72
Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L
Steering Stem Nut 4.9 0.50 43 in·lb T
Handlebar Holder Nuts 34 3.5 25 R
Front Fork Clamp Bolts (Lower) 22 2.2 16 AL
Brake Hose Clamp Bolt 3.0 0.31 27 in·lb
Frame
Footpeg Bracket Bolts (Upper) (KX250ZD
54 5.5 40 L
∼ ZE)
Footpeg Bracket Bolts (Upper) (KX250ZF) 34 3.5 25 L
Footpeg Bracket Bolts (Lower) (KX250ZF) 16.5 1.68 12.2 L
Rear Frame Mounting Bolts 34 3.5 25
Electrical System
Regulator/Rectifier Nuts 10 1.02 89 in·lb R
Spark Plug 13 1.3 115 in·lb
Flywheel Nut Cap 3.5 0.36 31 in·lb
Magneto Cover Bolts 9.8 1.0 87 in·lb
Timing Inspection Cap 3.5 0.36 31 in·lb
Flywheel Nut 78.5 8.00 57.9
Stator Coil Bolts 9.8 1.0 87 in·lb L
Crankshaft Sensor Bolts 7.0 0.71 62 in·lb L
Gear Position Switch Screws 2.9 0.30 26 in·lb L
Basic Torque for General Fasteners

Threads Diameter Torque
(mm) N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
8 14 ∼ 19 1.4 ∼ 1.9 10 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23.0 ∼ 33.0 165 ∼ 240
Specifications
Item Standard Service Limit

Fuel System (DFI)
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –
Idle Speed 2 050 ±50 r/min (rpm) – – –
Air Cleaner Element Oil High quality foam air filter oil – – –
Cooling System
Coolant:
Type (Recommended) Permanent type antifreeze – – –
Color Green – – –
Mixed Ratio Soft water 50%, coolant 50% – – –
Freezing Point –35°C (–31°F) – – –
Total Amount 1.2 L (1.3 US qt) – – –
Engine Top End
Valve Clearance:
Exhaust 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.) – – –
Intake 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) – – –
Cylinder Head Warp ––– 0.05 mm
(0.002 in.)
Cylinder Inside Diameter (see text):
KX250ZD ∼ ZE 77.000 ∼ 77.012 mm 77.10 mm
(3.0315 ∼ 3.0320 in.) (3.035 in.)
KX250ZF 76.998 ∼ 77.014 mm 77.10 mm
(3.0314 ∼ 3.0320 in.) (3.035 in.)
Piston/Cylinder Clearance 0.041 ∼ 0.068 mm – – –
(0.0016 ∼ 0.0027 in.)
Clutch
Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – –
Friction Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.5 mm (0.10 in.)
Friction Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
Engine Oil:
Type Castrol “POWER1 Racing 4T” 5W-40 or – – –
API SG, SH, SJ, SL or SM with JASO
MA, MA1 or MA2
Viscosity SAE 10W-30, 10W-40, or 10W-50 – – –
Capacity 0.75 L (0.79 US qt) (when filter is not – – –
removed)
0.80 L (0.85 US qt) (when filter is – – –
removed)
1.00 L (1.06 US qt) (when engine is – – –
completely dry)
Connecting Rod Big End Side 0.25 ∼ 0.35 mm 0.6 mm
Clearance (0.0098 ∼ 0.0138 in.) (0.02 in.)
Specifications

Wheels/Tires
Rim Runout (with tire installed):
Axial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm
(0.08 in.)
Radial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm
(0.08 in.)
Tires Air Pressure (Front/Rear) 100 kPa (1.00 kgf/cm², 14 psi) – – –
Standard Tire:
Front:
Size 80/100-21 51M – – –
Make DUNLOP – – –
Type MX51FA, Tube – – –
Rear:
Size 100/90-19 57M – – –
Type MX51, Tube – – –
Final Drive
Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – –
Drive Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)
Rear Sprocket Warp (Runout) TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm
(0.020 in.)
Brakes
Brake Lever Free Play Adjustable (to suit rider) – – –
Brake Fluid Type:
Front DOT3 or DOT4 – – –
Rear DOT3 or DOT4 – – –
Brake Pad Lining Thickness:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.)
Suspension
Front Fork
KX250ZD
Suspension Oil Kawasaki SS-19 or equivalent –––
Amount (Left Front Fork):
Cylinder Unit 330 mL (11.16 US oz.) – – –
Cylinder Unit Oil Level 115 ∼ 123 mm (4.53 ∼ 4.84 in.) – – –
Outer Tube 320 ±2.5 mL (10.82 ±0.085 US oz.) (Adjustable Range)
(EUR, BR) 300 ±2.5 mL (10.14 ±0.085 300 ∼ 340 mL
US oz.) (10.14 ∼ 11.50
US oz.)
Amount (Right Front Fork) 235 ±2.5 mL (7.95 ±0.085 US oz.) (Adjustable Range)
230 ∼ 378 mL
(7.78 ∼ 12.78
US oz.)
KX250ZE ∼
Suspension Oil Kawasaki SS-19 or equivalent
Specifications

Cylinder Unit 330 mL (11.16 US oz.)
Cylinder Unit Oil Level 115 ∼ 123 mm (4.53 ∼ 4.84 in.)
300 ∼ 340 mL
(10.14 ∼ 11.50
US oz.)
218 ∼ 366 mL
(7.37 ∼ 12.37
US oz.)
Rear Shock Absorber
Suspension Oil Kawasaki SS-25 or equivalent – – –
Amount approx. 380 mL (12.8 US oz.) – – –
Electrical System
Spark Plug Gap 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.) – – –
Special Tools
Inside Circlip Pliers: Filler Cap Driver:
57001-143 57001-1454
Steering Stem Nut Wrench: Fork Spring Compressor:

57001-1100 57001-1587
Jack: Jack Attachment:

57001-1238 57001-1608
Fork Piston Rod Puller, M12 × 1.25: Top Plug Wrench, 50 mm:
57001-1289 57001-1645
Fork Oil Level Gauge: Top Plug Wrench, 36 mm:

57001-1290 57001-1705
Special Tools
Fork Spring Compressor: Fork Piston Rod Puller Adapter:
57001-1771 57001-1791
Periodic Maintenance Procedures
Fuel System (DFI)
Fuel Hose and Connections Inspection
○If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the
hose burst. Remove the fuel tank (see Fuel Tank Re-
moval in the Fuel System (DFI) chapter) and check the
fuel hose.
Replace the fuel hose if any fraying, cracks [B] or bulges
[C] are noticed.
• Check that the fuel hose is routed according to Cable,
Wire, and Hose Routing section in the Appendix chapter.
• When installing the fuel hose, avoid sharp bending, kink-
ing, flattening or twist, and run the fuel hose with a mini-
mum of bending so that fuel flow will not be obstructed.
Replace the hose if it has been sharply bent or kinked.
Throttle Grip (Throttle Cable) Free Play Inspection
• Check the throttle grip free play [A] by lightly turning the
throttle grip [B] back and forth.
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
If the free play is improper, adjust the throttle cable.
• Check that the throttle grip moves smoothly from full open
to close, and the throttle closes quickly and completely in
all steering positions by the return spring.
If the throttle grip does not return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
• Run the engine at the idle speed, and turn the handlebars
all the way to the right and left to ensure that the idle speed
does not change.
If the idle speed increase, check the throttle cable free
play and the cable routing.
Throttle Grip (Throttle Cable) Free Play
Adjustment
• Loosen
cable.
the locknut [A] at the upper end of the throttle
• Screw the throttle cable adjuster [B] to give the throttle

grip plenty of play.
• Tighten the locknut.
If the throttle grip free play cannot be adjusted with the

adjuster, replace the throttle cables.
• Turn the handlebars from side to side while idling the en-
gine. If idle speed varies, the throttle cable may be poorly
routed or it may be damaged.
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition. Follow the service manual to
make sure to correct any of these conditions.
Throttle Body Cleaning
•○Check the throttle bore for cleanliness as follows.
Remove the throttle body assy (see Throttle Body Assy
Removal in the Fuel System (DFI) chapter).
○Check the throttle bore [A] at the throttle valve for carbon
deposits by opening the throttle valve.
If any carbon accumulates, wipe the carbon off the throt-
tle bore and the throttle valve, using a lint-free cloth pen-
etrated with a high flash-point solvent.
Fuel Hose Replacement

• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
• Be sure to place a piece of cloth around each fuel hose
joint.
• Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.
Throttle Body Assy Side

When removing with standard tip screwdriver:
•Insert the standard tip screwdriver [A] into the slit [B] on
the joint lock [C].
•Turn the driver to disconnect the joint lock.
When removing with fingers:

•Open and push up [A] the joint lock [B] with your fingers.
NOTICE
Prying or excessively widening the joint lock ends
for fuel hose removal will permanently deform the
joint lock, resulting in a loose or incomplete lock
that may allow fuel to leak and create the potential
for a fire explosion. To prevent fire or explosion
from a damaged joint lock, do not pry or excessively
widen the joint lock ends when removing the fuel
hose. The joint lock has a retaining edge that locks
around the housing.
• Pull the fuel hose joint [A] out of the delivery pipe.
WARNING
Fuel is flammable and explosive under certain con-
ditions and can cause severe burns. Be prepared
for fuel spillage; any spilled fuel must be completely
wiped up immediately. When the fuel hose is dis-
connected, fuel spills out from the hose and the
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
• Clean the delivery pipe.

• Cover the delivery pipe with the vinyl bag to keep it clean.
Air Cleaner Side
the joint lock [C].

NOTICE
around the housing.
• Pull the fuel hose joint [A] out of the delivery pipe.
WARNING
pipe. Cover the hose connection with a clean shop
towel to prevent fuel spillage.
• Clean the delivery pipe.

• Cover the delivery pipe with the vinyl bag to keep it clean.
• Remove the vinyl bag on each delivery pipe.

• foreign materials
Check that there are no flaws, burrs, and adhesion of
on each delivery pipe [A].
• Run the fuel hose correctly
Replace the fuel hose with a new one.
• Routing section in the Appendix(see Cable, Wire, and Hose
chapter).
• Apply engine oil to the fuel outlet pipe [A] lightly.
• Insert [A] the fuel hose joint [B] straight onto the delivery
pipe until the hose joint clicks.
• Push [C] the joint lock [D].
Throttle Body Assy Side [E]
Air Cleaner Side [F]
• Push and pull [A] the fuel hose joint back and forth more
than two times and make sure it is locked and does not
come off.
Throttle Body Assy Side [B]
Air Cleaner Side [C]
WARNING
Leaking fuel can cause a fire or explosion resulting
in severe burns. Make sure the fuel hose joint is
installed correctly on the delivery pipe and that it
doesn’t leak.
If it comes off, reinstall the hose joint.
• Install the fuel tank (see Fuel Tank Installation in the Fuel
System (DFI) chapter).
• Start the engine and check the fuel hose for leaks.
Idle Speed Inspection

NOTICE
This motorcycle is designed for competition use
only. Therefore, the radiator does not incorporate
a coolant reserve tank or cooling fan. Prolonged
idling of the engine with no airflow through the
radiator can cause coolant loss and engine over-
heating resulting in possible engine damage. Any
riding conditions that increase engine temperature
will further reduce idling time before coolant loss
occurs. These conditions include high ambient
temperature, sandy or muddy terrain, or other con-
ditions causing high engine loads at low speeds.
Furthermore, warming the engine up excessively
before operation, or leaving idling with the hot
engine temperature after operation results in the
engine overheating, too.
• Start the engine and warm it up thoroughly.

• [A]. engine idling, turn the handlebars to both sides
With the
If handlebars movement changes the idle speed, the

throttle cable may be improperly adjusted or incorrectly
routed, or it may be damaged. Be sure to correct any
of these conditions before riding (see Cable, Wire, and
Hose Routing section in the Appendix chapter).
WARNING
• Check the idle speed, using the engine revolution tester

[A] for high accuracy.
If the idle speed is out of specified range, adjust it.
Idle Speed
Standard: 2 050 ±50 r/min (rpm)
Idle Speed Adjustment

• Turn the idle adjusting screw [A] until the idle speed is
correct.
To increase idle speed [B]
To decrease idle speed [C]
• Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Air Cleaner Element Cleaning and Inspection

NOTE
○In dusty areas, the element should be cleaned more
frequently than recommended interval.
○After riding through rain or on muddy roads, the element
should be cleaned immediately.
○Since repeated cleaning opens the pores of the ele-
ment, replace it with a new one in accordance with the
Periodic Maintenance Chart. Also, if there is a break in
the element material or any other damage to the ele-
ment, replace the element with a new one.
WARNING
Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the element in a well-ventilated area,
and take care that there is no spark or flame any-
where near the working areas. Do not use gasoline
or low flash-point solvents to clean the element.
• Remove:
Seat (see Seat Removal in the Frame chapter)
Wing Bolt [A]
Air Cleaner Element [B]
• Stuff a clean, lint-free towel into the air cleaner duct so no
dirt is allowed to enter the throttle body assy.
• Wipe out the inside of the air cleaner housing with a clean
damp towel.
NOTICE
Check inside of the intake tract and throttle body
assy for dirt. If dirt is present, clean the intake tract
and throttle body assy thoroughly. You may also
need to replace the element and seal the housing
and intake tract.
• Separate the element [A] from the frame [B].
• Clean the element [A] in a bath of a high flash-point sol-

vent using a soft bristle brush.
• Squeeze it dry in a clean towel [A]. Do not wring the ele-

ment or blow it dry; the element can be damaged.
• Check all parts of the element for visible damage.
If any parts of the element are damaged, replace them.
• After cleaning, saturate the element with a high-quality

foam-air-filter oil, squeeze out the excess, then wrap it in
a clean towel and squeeze it as dry as possible.
○Be careful not to tear the sponge filter.
• Assemble the element.
• Remove the towel from the air cleaner duct.
• Apply grease to all connections and screw holes in the air

cleaner housing and intake tract.
• Install the element onto its frame, and coat the element
lip and lip seat with a thick layer of all-purpose grease to
assure a complete seal.
• Install the air cleaner element so that its tab [A] faces
upward and its projections [B] align with the holes [C] of
the air cleaner housing.
• Tighten the wing bolt securely.
• Install the seat (see Seat Installation in the Frame chap-
ter).
Fuel Tank Cleaning

WARNING
burns. Clean the tank in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area. Do not use gasoline
or low flash-point solvents to clean the tank.
• Remove the fuel tank and drain the fuel (see Fuel Tank
Removal in the Fuel System (DFI) chapter).
• Remove the fuel pump (see Fuel Pump Removal in the
Fuel System (DFI) chapter).
• Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
• Drain the solvent out of the tank.
• Dry the tank with compressed air.
• Fuel System
Install the fuel pump (see Fuel Pump Installation in the
(DFI) chapter).
• System (DFI) chapter).
Install the fuel tank (see Fuel Tank Installation in the Fuel
Cooling System
WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambi-
ent temperature).
• Remove the right radiator shroud (see Radiator Shroud

Removal in the Frame chapter).
• Lean the motorcycle slightly until the radiator cap is level
to the ground so that the radiator cap is located uppermost
in order to exhaust the air accumulated in the radiator.
• Remove the radiator cap [A].
NOTE
○Remove the radiator cap in two steps. First turn the
cap counterclockwise to the first stop and wait there for
a few seconds. Then push down and turn it further in
the same direction and remove the cap.
• Check the coolant level. The coolant level [A] should be

at the bottom of the filler neck [B].
If the coolant level is low, add coolant through the filler
opening to the bottom of the filler neck. Install the cap.
Recommended Coolant
Permanent type antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
Water and Coolant Mixture Ratio
Soft Water: 50%
Coolant: 50%
Freezing Point: –35°C (–31°F)
Total Amount: 1.2 L (1.3 US qt)
NOTICE
For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
Coolant Deterioration Inspection
• Visually inspect the coolant.
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Water Hoses and Connections Inspection
• Remove the radiator shrouds (see Radiator Shroud Re-
moval in the Frame chapter).
○The high pressure inside the water hoses [A] can cause
coolant to leak [B] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [C] or bulges [D]
are noticed.
• Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)
Engine Top End

Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (at room temperature).
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Timing Inspection Cap [A]
Flywheel Nut Cap [B]
Special Tool - Filler Cap Driver: 57001-1454
• Bring the piston to the TDC of the compression stroke to

inspect the valve clearance (the position at the end of the
compression stroke), when the cam lobe faces outside of
the camshaft.
○Place a wrench over the flywheel nut [A] and turn it coun-
terclockwise to align the TDC mark [B] with the center of
the groove [C] of the inspection hole.
• Using a thickness gauge [A], measure the clearance be-

tween each cam lobe and valve lifter for all 4 valves.
○For the purpose of adjusting the valve clearances, record
the measured values.
Valve Clearance
Standard:
Exhaust 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)
Intake 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)
If the valve clearance is not within the specified range,
adjust it.
Valve Clearance Adjustment
• Remove:
Camshaft Cap [A] (see Camshaft Removal in the Engine
Top End chapter)
Camshafts [B] (see Camshaft Removal in the Engine
Top End chapter)
• Remove the valve lifters [C] of the applicable valve.
• Remove the shims [D].
NOTE
○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.
• Clean the shim to remove any dust or oil.

• Select a new
Measure the thickness of the removed shim [A].
• a + b – c = dshim thickness calculation as follows.
[a] Present Shim Thickness
[b] Measured Valve Clearance
[c] Specified Valve Clearance (Mean Value)
Exhaust 0.195 mm
Intake 0.125 mm
[d] Replace Shim Thickness
Example (Intake):
2.60 + 0.31 – 0.125 = 2.785 mm
○Exchange the shims for the 2.800 size shim.
NOTICE
Do not use the shims for another models. This
could cause wear of the valve stem end and the
valve stem damage.
Adjustment Shims
Thick- Thick-
P/No. Mark P/No. Mark
ness ness
2.500 92180-0167 250 3.025 92180-0188 302
2.525 92180-0168 252 3.050 92180-0189 305
2.550 92180-0169 255 3.075 92180-0190 308
2.575 92180-0170 258 3.100 92180-0191 310
2.600 92180-0171 260 3.125 92180-0192 312
2.625 92180-0172 262 3.150 92180-0193 315
2.650 92180-0173 265 3.175 92180-0194 318
2.675 92180-0174 268 3.200 92180-0195 320
2.700 92180-0175 270 3.225 92180-0196 322
2.725 92180-0176 272 3.250 92180-0197 325
2.750 92180-0177 275 3.275 92180-0198 328
2.775 92180-0178 278 3.300 92180-0199 330
2.800 92180-0179 280 3.325 92180-0200 332
2.825 92180-0180 282 3.350 92180-0201 335
2.850 92180-0181 285 3.375 92180-0202 338
2.875 92180-0182 288 3.400 92180-0203 340
2.900 92180-0183 290 3.425 92180-0204 342
2.925 92180-0184 292 3.450 92180-0205 345
2.950 92180-0185 295 3.475 92180-0206 348
2.975 92180-0186 298 3.500 92180-0207 350
3.000 92180-0187 300
NOTE
○Be sure to remeasure the clearance after selecting a
shim. The clearance can be out of the specified range
because of the shim tolerance.
○If there is no valve clearance, use a shim that is a few
sizes smaller, and remeasure the valve clearance.
•○Install the shim.

Turn the marked side [A] to upside.
○Apply engine oil to the shim to keep the shim in place
during camshaft installation.
NOTICE
Do not put shim stock under the shim. This may
cause the shim to pop out at high rpm, causing ex-
tensive engine damage.
Do not grind the shim. This may cause it to fracture,
causing extensive engine damage.
• Apply engine oil to the valve lifter [B] surface and install
the lifter.
• Install:
Camshafts (see Camshaft Installation in the Engine Top
End chapter)
Camshaft Cap (see Camshaft Installation in the Engine
Top End chapter)
• Recheck the valve clearance and readjust if necessary.
• Install the removed parts (see appropriate chapters).
Cylinder Head Warp Inspection
• Remove the cylinder head (see Cylinder Head Removal
in the Engine Top End chapter).
• Lay a straightedge [A] across the lower surface of the
head at several different points, and measure warp by
inserting a thickness gauge [B] between the straightedge
and head.
Cylinder Head Warp
Service Limit: 0.05 mm (0.002 in.)
If warp exceeds the service limit, repair the mating sur-
face. Replace the cylinder head if the mating surface is
badly damaged.
• Remove the valves (see Valve Removal in the Engine Top

End chapter).
• Scrape the carbon out of the combustion chamber and
exhaust port with a scraper [A] or a suitable tool.
• Clean the cylinder head, using high flash-point solvent.
• in the cylinder
Blow out any particles which may obstruct the oil passage
head using compressed air.
• Install the valves (see Valve Installation in the Engine Top
End chapter).
Cylinder Wear Inspection

NOTE
○Measure the cylinder inside diameter when the cylinder
is cold (at room temperature).
• Visually inspect the inside of the cylinder for scratches

and abnormal wear.
If the cylinder is damaged or badly worn, replace it with a
new one.
• Take a side-to-side and a front-to-back measurement as

shown (total 6 measurements).
○The cylinder wear is uneven in different places.
10 mm (0.39 in.) [A]
25 mm (0.98 in.) [B]
60 mm (2.36 in.) [C]
Cylinder Inside Diameter

Standard:
KX250ZD ∼ ZE 77.000 ∼ 77.012 mm (3.0315 ∼ 3.0320
in.), and less than 0.01 mm (0.0004
in.) difference between any two
measurements.
KX250ZF 76.998 ∼ 77.014 mm (3.0314 ∼ 3.0320
in.), and less than 0.01 mm (0.0004
in.) difference between any two
measurements.
Service Limit: 77.10 mm (3.035 in.), or more than
0.05 mm (0.0020 in.) difference
between any two measurements.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, the cylinder must be replaced with
a new one.
○Since the PLATING cylinder cannot be bored or honed.
Piston/Cylinder Clearance Inspection
The piston/cylinder clearance is measured whenever a
piston or cylinder is replaced with a new one. The standard
piston/cylinder clearance must be adhered to whenever the
cylinder is replaced.
If only a piston is replaced, the clearance may exceed the
standard slightly. But it must be within the standard, in order
to avoid piston seizure.
The most accurate way to find the piston clearance is
by making separate piston and cylinder diameter measure-
ments and then computing the difference between the two
values. Measure the piston diameter as just described, and
measure the cylinder diameter at the very bottom of the
cylinder.
Piston/Cylinder Clearance
Standard: 0.041 ∼ 0.068 mm (0.0016 ∼ 0.0027 in.)
Piston, Piston Ring and Piston Pin Replacement

• Refer to the Cylinder and Piston section in the Engine Top
End chapter.
Exhaust System Inspection
• The exhaust system, in particular the muffler body, is de-
signed to reduce exhaust noise and conduct the exhaust
gases away from the rider while minimizing power loss. If
carbon has built up inside the muffler body, exhaust effi-
ciency is reduced, causing engine performance to drop.
If the muffler body is badly damaged, dented, cracked or
rusted, replace it.
If the exhaust noise becomes too loud or engine perfor-
mance drops, replace the silencer wool.
Silencer Wool Replacement
• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Muffler Body Cover Bolts [A]
Muffler Mounting Bolt [B]
•○Remove the muffler cover [A].

Tap the bracket [B] with a plastic mallet [C] to separate
the cover and pipe.
• Replace the silencer wool with a new one.
• Clean the adhered silicone sealant.
•○Insert the new silencer wool [A] and muffler cover [B].
Fit the pipe end [C] and exhaust hole of the baffle.
• Apply a non-permanent locking agent to the threads of
the muffler cover bolts, and tighten them.
• Tighten the muffler mounting bolt securely.
• Using a high flash-point solvent, clean off any oil or dirt

that may be on the silicone sealant coating area. Dry
them with a clean cloth.
• Apply silicone sealant to the mating surface [A].
• Install the right side cover (see Side Cover Installation in
the Frame chapter).
Clutch
Clutch Operation Inspection
Clutch Lever (Clutch Cable) Free Play Inspection
•Slide the clutch cable adjuster knob [A] out of place.
•Check that the clutch cable upper end [B] is fully seated
in the adjusting bolt [C].
•Install the knob to original position.
• Pull the clutch lever [A] lightly, and check the flee play [B].
Clutch Lever Free Play
Standard: 8 ∼ 13 mm (0.3 ∼ 0.5 in.)
If the play is too wide, the clutch may not release fully. If
the play is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever (Clutch Cable) Free Play Adjustment

•Turn the clutch cable adjuster knob [A] so that the clutch
lever will have 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play.
NOTICE
Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into the place later, creating enough
cable play to prevent clutch disengagement.
If the free play can not be adjusted with the clutch cable
adjuster, use the adjusting nut.
• Slide the dust cover [A].

• Loosen the locknut [B] at the clutch cable, and turn the
adjusting nut [C] so that clutch lever has 8 ∼ 13 mm (0.3
∼ 0.5 in.) of play.
• Tighten the locknut, and start the engine and check that
the clutch does not slip and that it release properly.
Clutch Plates Inspection

• Remove the clutch plates (see Clutch Removal in the
Clutch chapter).
• Visually inspect the friction and steel plates to see if they
show signs of seizure, uneven wear or any other damage.
If any plates show signs of damage, replace the friction
plates and steel plates as a set.
• Measure the thickness [A] of the friction and at several

points with vernier calipers.
Friction Plate Thickness
Standard: 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.)
If they have worn past the service limit, replace them with
new ones.
• Place
[A].
each friction plate or steel plate on a surface plate
• Measure the gap between the surface plate and each fric-
tion plate or steel plate [B] with a thickness gauge [C]. The
gap is the amount of friction or steel plate warp.
Friction and Steel Plates Warp
Standard:
Friction Plate 0.15 mm (0.0059 in.) or less
Steel Plate 0.15 mm (0.0059 in.) or less
Service Limit:
Friction Plate 0.3 mm (0.012 in.)
Steel Plate 0.3 mm (0.012 in.)
If any plate is warped over the service limit, replace it with
a new one.

WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
Engine Oil Change

• Warm up the engine thoroughly so that the oil will pick up
any sediment and drain easily. Then stop the engine.
• Place an oil pan beneath the engine.
• Remove the oil filler plug [A].
• Remove the engine oil drain bolt [A] from the bottom of
the engine, and let the oil drain completely.
NOTE
○Hold the motorcycle upright so that the oil may drain
completely.
• Replace the drain bolt gasket with a new one.

• Install the drain bolt with the gasket.
• Tighten:
Torque - Engine Oil Drain Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)
• Pour in the specified type and amount of oil.

Recommended Engine Oil
Type: Castrol “POWER1 Racing 4T” 5W-40 or
API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
Viscosity: SAE 10W-30, 10W-40, or 10W-50
Capacity: 0.75 L (0.79 US qt) (when filter is not
removed)
0.80 L (0.85 US qt) (when filter is removed)
1.00 L (1.06 US qt) (when engine is
completely dry)
NOTE
○Do not add any chemical additive to the oil. Oils fulfilling
the above requirements are fully formulated and provide
adequate lubrication for both the engine and the clutch.
○The oil viscosity may need to be changed to accommo-
date atmospheric conditions in your riding area.
• Check the oil level (see Oil Level Inspection in the Engine
Lubrication System chapter).
• Replace the oil filler plug O-ring with a new one.
• Tighten: to the O-ring.
Apply grease
•
Torque - Oil Filler Plug: 3.5 N·m (0.36 kgf·m, 31 in·lb)
Oil Filter Change

• Drain:
Engine Oil (see Engine Oil Change)
• Oil Filter Cap Bolts [A]
Remove:
Oil Filter Cap [B]

• Remove the oil filter [A].
• Replace the oil filter with a new one.

• Install the oil filter.
Apply grease to the grommet [A].
•○Turn the grommet to inside.
NOTICE
Inside out installation stop oil flow, causing engine
seizure.
• Replace the oil filter cap O-ring [A] with a new one.
• Install:
Apply grease to the O-ring.
• Spring [B]
Oil Filter Cap
• Tighten:
Torque - Oil Filter Cap Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Pour the specified engine oil (see Engine Oil Change).
Breather Hose Inspection
• Be certain that the breather hose [A] are routed without
being flattened or kinked and is connected correctly.
If it is not, correct it.
•Inspect the breather hose for damage or signs of deteri-
oration.
○This hose should not be hard and brittle, nor should be
soft swollen.
Replace it if any damage is noticed.
Crankshaft Inspection
• Remove:
Cylinder Head (see Cylinder Head Removal in the En-
gine Top End chapter)
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Piston (see Piston Removal in the Engine Top End chap-
ter)
• Make sure that the crankshaft rotate [A] smoothly (in the
neutral position).
If the crankshaft will not turn smoothly, check the connect-
ing rod big end side clearance.
If the connecting rod big end side clearance is good,
check the bearings (see Bearing Inspection in the Crank-
shaft/Transmission chapter).
Connecting Rod Big End Side Clearance
•Measure the connecting rod big end side clearance at
right side of big end using a thickness gauge [A].
Connecting Rod Big End Side Clearance
Standard: 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.)
If the clearance exceeds the service limit, replace the
crankshaft assembly or reassemble the crankshaft.
• Make sure that the crankshaft rotates smoothly after as-
sembling the engine.
Wheels/Tires
Air Pressure Inspection/Adjustment
• Using an air pressure gauge [A], measure the air pressure
when the tires are cold.
• Adjust the tire air pressure to suit track conditions and
rider preference, but do not stray too far from the recom-
mended pressure.
Track Condition Tire Pressure
When the track is wet, muddy, sandy
80 kPa (0.8 kgf/cm²,
or slippery, reduce the tire pressure
12 psi)
to increase the tire tread surface on
↑
the ground.
When the track is pebbly or hard,
↓
increase the tire pressure to prevent
100 kPa (1.0 kgf/cm²,
damage or punctures, through the
14 psi)
tires will skid more easily.
Tires Inspection
• Remove any imbedded stones or other foreign particles
from the tread.
Repair or replace with a new one if necessary.
•Visually inspect the tire for cracks and cuts.
Replace the tire, if any damage are noticed.
○Swelling or high spots indicate internal damage, requiring
tire replacement.
WARNING
Some replacement tires may adversely affect han-
dling and cause an accident resulting in serious in-
jury or death. To ensure proper handling and sta-
bility, use only the recommended standard tires for
replacement, inflated to the standard pressure.
NOTE
○Check and balance the wheel when a tire is replaced
with a new one.
Standard Tire
Front:
Size 80/100-21 51M
Make DUNLOP
Type MX51FA, Tube
Rear:
Size 100/90-19 57M
Make DUNLOP
Type MX51, Tube
Spoke Tightness Inspection

• Check that all the spokes are tightened evenly.
If spoke tightness is uneven or loose, tighten the spoke
nipples evenly.
Torque - Spoke Nipples: 2.2 N·m (0.22 kgf·m, 19 in·lb)
• Check the rim runout (see Rim Runout Inspection).
WARNING
A missing spoke places an additional load on
the other spokes, which will eventually cause
other spokes to break, creating the potential for
an accident resulting in serious injury or death.
Immediately replace any broken spoke(s).
Rim Runout Inspection

• Place the jack under the frame so that the front/rear wheel
off the ground.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Inspect the rim for cracks, dents, bending, or warping.
If there is any damage to the rim, it must be replaced.
• Set a dial gauge against the side of the rim, and rotate the
rim to measure the axial runout [A].
○The difference between the highest and lowest dial read-
ings is the amount of runout.
• Set a dial gauge against the outer circumference of the
rim, and rotate the rim to measure radial runout [B].
Rim Runout (with tire installed)
Standard:
Axial TIR 1.0 mm (0.04 in.) or less
Radial TIR 1.0 mm (0.04 in.) or less
Service Limit:
Axial TIR 2.0 mm (0.08 in.)
Radial TIR 2.0 mm (0.08 in.)
If rim runout exceeds the service limit, check the wheel
bearings first.
If the problem is not due to the bearings, loosen some
spokes and tighten others within the standard torque.
Wheel Bearing Inspection
• Raise the front/rear wheel off the ground using the jack.
• Rotate [A] the wheel lightly, and check for roughness,
binding or noise.
If any damage is found, replace the hub bearing.
• Turn the handlebars until the handlebars does not move

to either side (front wheel).
• The wheel edge is moved [A] to one direction gripping the
edge of the wheel by both hands and the play of the wheel
bearing is checked.
If the play is found, replace the bearing.
Final Drive
Drive Chain Wear Inspection
• Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
Bushing [A]
Roller [B]
Pin [C]
Pin Link [D]
Roller Link [E]
• Stretch the chain taut by hanging a 10 kg (22 lb) weight

[A] on the chain.
• Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
Chain 20-link Length
Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit: 323 mm (12.7 in.)
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain.
Standard Chain
Make: DAIDO
Type: DID 520DMA4
Link: 114 links
Drive Chain Slack Inspection

• Using the jack, raise the rear wheel until the rear shock
absorber stretched fully.
• Check the wheel alignment (see Wheel Alignment Inspec-
tion in the Final Drive chapter), and adjust it if necessary
(see Wheel Alignment Adjustment in the Final Drive chap-
ter).
NOTE
○Clean the drive chain if it is dirty, and lubricate it if it
appears dry.
• Rotate the rear wheel to find the position where the chain
is tightest (because it wears unevenly).
• Measure the space (chain slack) [A] between the bottom
of the chain and the rear of the chain slipper.
Chain Slack
Standard: 52 ∼ 58 mm (2.0 ∼ 2.3 in.)
If the drive chain slack exceeds the standard, adjust it.
Rear Axle Nut Inspection (KX250ZF)
• Visually inspect the rear axle nut for deformation or dam-
age at the friction ring [A] and caulking [B]. If it is deformed
or damaged, replace the axle nut with a new one.
Drive Chain Slack Adjustment

• Loosen the left and right chain adjuster locknuts [A].
• Remove the cotter pin [B] (KX250ZD ∼ ZE).
• If the chain rear
Loosen the axle nut [C].
is too tight, back out the left and right chain
adjusting bolts [D] evenly, and push the wheel forward
until the chain is too loose.
If the chain is too loose, turn both chain adjusting bolts
evenly until the drive chain has the correct amount of
slack. To keep the chain and wheel properly aligned, the
notch on the left chain adjuster should align with the same
swingarm mark [E] as the right chain adjuster notch [F].
• Check the wheel alignment (see Wheel Alignment Inspec-
tion in the Final Drive chapter).
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
• Tighten both chain adjuster locknuts securely.

• spection) (KX250ZF).
Inspect the rear axle nut (see the the Rear Axle Nut In-
• Tighten:
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb)
• Rotate the wheel, measure the chain slack again at the
tightest position, and readjust if necessary.
KX250ZD ∼ ZE
•Insert a new cotter pin [A].
NOTE
○When 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 [B] up to next alignment.
○It should be within 30 degrees.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut.

WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.
• Check the rear brake effectiveness.

NOTE
○In wet and muddy conditions, mud sticks to the chain
and sprockets resulting in an overly tight chain, and the
chain may break. To prevent this, adjust the chain to 62
∼ 68 mm (2.4 ∼ 2.7 in.) of slack whenever necessary.
Drive Chain Lubrication

○The chain should be lubricated with a lubricant which will
both prevent the exterior from rusting and also absorb
shock and reduce friction in the interior of the chain.
If the chain is especially dirty, it should be washed in
diesel oil or kerosene, and afterward soaked in a heavy
oil. Shake the chain while it is in the oil so that oil will pen-
etrate into the inside of each roller.
• An effective, good quality lubricant specially formulated
for chains is best for regular chain lubrication.
• IfSAE90
a special lubricant is not available, a heavy oil such as
is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
• Apply oil to the sides of the rollers so that oil will penetrate
into the rollers and bushings.
• Wipe off any excess oil.
Oil Applied Area [A]
Sprocket Wear Inspection

• Visually inspect the front and rear sprocket teeth for wear
and damage.
If they are worn as illustrated or damaged, replace the
sprocket, and inspect the drive chain wear.
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
NOTE
○If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.
Rear Sprocket Warp (Runout) Inspection
• Using the jack, raise the rear wheel off the ground.
• Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown.
• Rotate [C] the rear wheel slowly to measure the sprocket
warp (runout).
○The difference between the highest and lowest dial gauge
readings is the amount of warp (runout).
Rear Sprocket Warp (Runout)
Standard: TIR 0.4 mm (0.016 in.) or less
Service Limit: TIR 0.5 mm (0.020 in.)
If the runout exceeds the service limit, replace the rear
sprocket.
Brakes
Brake Lever and Pedal Adjustment
•○Adjust the brake lever to suit you.
Loosen the adjuster locknut [B] and turn the adjuster [C]
to either side.
• After adjustment, tighten the locknut.
WARNING
An improperly adjusted brake could drag and cause
the brake to overheat, damaging the brake assem-
bly and possbily locking the rear wheel, resulting in
loss of control. Always maintain the proper brake
adjustment.
NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when the master cylinder is disas-
sembled or pedal position is incorrect.
• Measure the length [A].

Rear Master Cylinder Push Rod Length
Standard: 68.5 ±1 mm (2.70 ±0.04 in.)
If it is not within the standard, adjust the push rod in the
master cylinder as follows.
○Loosen the push rod locknut [A].

○Turn the adjusting bolt [B] to obtain the specified length.
○Tighten the locknut.
Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m
(1.7 kgf·m, 13 ft·lb)
Brake Fluid Level Inspection
• Check the brake fluid level in the front or rear brake reser-
voir [A] and the front or rear reservoir must be kept above
the lower level line [B].
NOTE
○Hold the reservoir horizontal when checking brake fluid
level.
If the fluid level in front or rear reservoir is lower than the
lower level line, fill the reservoir to the upper level line.
• Inside the reservoir is stopped end showing the upper
level line [C].
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
Brake Fluid Change
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been
left unsealed or that has been open for a long
time.
3. Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffec-
tive. It may also cause the rubber brake parts to
deteriorate.
4. Don’t leave the reservoir cap off for any length
of time to avoid moisture contamination of the
fluid.
5. Don’t change the fluid in the rain or when a
strong wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol
for cleaning of the brake parts. Do not use any
other fluid for cleaning these parts. Gasoline,
engine oil, or any other petroleum distillate will
cause deterioration of the rubber parts. Oil
spilled on any part will be difficult to wash off
completely and will eventually deteriorate the
rubber used in the disc brake.
7. When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets
on the pads or disc with a high flash-point sol-
vent. Do not use one which will leave an oily
residue. Replace the pads with new ones if they
cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up im-
mediately.
9. If any of the brake line fittings or the bleed valve
is opened at any time, the AIR MUST BE BLED
FROM THE BRAKE LINE.
Recommended Disc Brake Fluid

Type:
Front and Rear DOT3 or DOT4
NOTE
○The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for
the front brake.
• Level the brake fluid reservoir.

• Screws [A]
Remove:
Reservoir Cap [B]

Diaphragm
• Remove the rubber cap [A] on the bleed valve [B].
• Attach a clear plastic hose [A] to the bleed valve on the

caliper, and run the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
•○Change the brake fluid as follows:

Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].
WARNING
Mixing brands and types of brake fluid can reduce
the brake system’s effectiveness and cause an ac-
cident resulting in injury or death. Do not mix two
brands of brake fluid. Change the brake fluid in the
brake line completely if the brake fluid must be re-
filled but the type and brand of the brake fluid that
is already in the reservoir are unidentified.
NOTE
○The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
• Remove the clear plastic hose.

• Tighten: diaphragm and reservoir cap.
Install the
•
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Tighten the bleed valve, and install the rubber cap.
Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
• After changing the fluid, check the brake for good braking
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines (see Brake Line
Bleeding in the Brakes chapter).
Brake Pad Wear Inspection
• Check the lining thickness and condition of the brake pads
in each caliper.
NOTE
○It is able to check with the pads installed.
If either pad is damaged, replace both pads in the caliper
as a set.
Brake Pad Lining Thickness
Standard:
Front 4.0 mm (0.16 in.)
Rear 6.4 mm (0.25 in.)
Service Limit:
Front 1 mm (0.04 in.)
Rear 1 mm (0.04 in.)
If the lining thickness [A] of either pad is less than the
service limit [B], replace both pads in the caliper as a set.
Front Pad [C]
Rear Pad [D]
Brake Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
• Remove the front master cylinder (see Front Master Cylin-
der Removal in the Brakes chapter).
• Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
• Remove the locknut and pivot bolt, and remove the brake
lever.
• Pull the push rod [A] and dust cover [B] out of place, and
remove the circlip [C].
Special Tool - Inside Circlip Pliers: 57001-143
• Remove the washer [D].
• Remove the piston assy [E] (include primary and sec-
ondary cups).
Rear Master Cylinder Disassembly
•Remove the rear master cylinder (see Rear Master Cylin-
der Removal in the Brakes chapter).
NOTE
○Do not remove the push rod clevis since removal re-
quires brake pedal position adjustment.
• Remove the reservoir cap and diaphragm, and pour the

brake fluid into a container.
• Slide the dust cover [A] on the push rod [B] out of place,
and remove the circlip [C].
• Pull out the push rod.
• Remove the piston assy [D] (include primary and sec-
ondary cups).
Master Cylinder Assembly

•Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
NOTICE
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning of these parts. Gasoline, engine
oil, or any other petroleum distillate will cause de-
terioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely, and will
eventually deteriorate the rubber used in the disc
brake.
• Apply brake fluid to the removed parts and to the inner

wall of the cylinder.
• Take care not to scratch the piston assy and the inner wall
of the cylinder.
• Apply
parts.
silicone grease (ex. PBC grease) to the following
Brake Lever Pivot Bolt (Front)

Brake Lever Contact (Front)
Push Rod Contact
Dust Covers
• Tighten:
Torque - Brake Lever Pivot Bolt: 5.9 N·m (0.60 kgf·m, 52
in·lb)
Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Caliper Rubber Parts Replacement
Front Caliper Disassembly
• Remove:
Front Caliper (see Caliper Removal in the Brakes chap-
ter)
Brake Pads (see Brake Pad Removal in the Brakes
chapter)
• Separate the caliper holder [A] from the caliper [B].

• Remove the anti-rattle springs [C].
• Using compressed air, remove the pistons.

remove the pistons is as follows.
One way to
○Cover the caliper opening with a clean heavy cloth [A].

○Remove the pistons by lightly applying compressed air [B]
to the hose joint opening.
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
• Pull out the pistons [A] by hand.

• der. the dust seal [B] and fluid seal [C] on each cylin-
Remove
NOTE
○If compressed air is not available, with the brake hose
connected to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the spring and pads (see Brake Pad Removal
in the Brakes chapter).
○Pump the brake lever until the pistons come out of the
cylinders.
Rear Caliper Disassembly
•Remove:
Rear Caliper (see Caliper Removal in the Brakes chap-
ter)
Brake Pads (see Brake Pad Removal in the Brakes
chapter)
• Separate the caliper holder [A] from the caliper [B].

• Remove the anti-rattle springs [C].
•○Using compressed air, remove the piston.

Cover the caliper opening with a clean heavy cloth [A].
○Remove the piston by lightly applying compressed air [B]
to the hose joint opening.
WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.
• Pull out the piston [A] by hand.

• Remove the dust seal [B] and fluid seal [C].
Caliper Assembly
•Clean the caliper parts except for the pads.
NOTICE
For cleaning of the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
If you removed the bleed valve, install the bleed valve and
rubber cap.
•○Replace the fluid seal(s) [A] with new ones.

Apply silicone grease to the fluid seal(s), and install them
into the cylinder(s) by hand.
•Replace the dust seal(s) [B] with new ones.
○Apply brake fluid to the dust seal(s), and install them into
the cylinder(s) by hand.
•Apply brake fluid to the outside of the piston(s) [C], and
push them into each cylinder by hand.
• Install the anti-rattle springs [A].

• Replace
damaged.
the friction boot [A] and dust boot [B] if they are
• Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

the caliper holder shafts [C] and holder holes (PBC is a
special high-temperature, water-resistance grease).
• Assemble the caliper and caliper holder.
• Install the pads (see Brake Pad Installation in the Brakes

chapter).
• Install
chapter).
the caliper (see Caliper Installation in the Brakes
• Wipe
cloth.
up any spilled brake fluid on the caliper with wet
Brake Hoses and Connections Inspection

• Inspect the brake hose and
cracks and signs of leakage.
fittings for deterioration,
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are no-
ticed.
Tighten any loose fittings.
Brake Hose Replacement
NOTICE
Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely washed away
immediately.
Front Brake Hose
• Remove:
Brake Hose Clamp Bolts [A]
Brake Hose Clamps [B]
Rear Brake Hose

•Remove:
Bolts [A]
Caliper Guard [B]
Screws [C]
Brake Hose Clamp [D]
• Remove:
Screws [A]
Brake Hose Clamp [B]
Rear Master Cylinder Mounting Bolts [C]
• Remove the front/rear brake hose banjo bolts [A] and

washers [B].
•○Replace the washers with new ones.
When removing the brake hose, take care not to spill the
brake fluid on the painted or plastic parts.
○When removing the brake hose, temporarily secure the
end of the brake hose to some high place to keep fluid
loss to a minimum.
• When installing the hoses, avoid sharp bending, kink-

ing, flattening or twisting, and run the hoses according to
Cable, Wire, and Hose Routing section in the Appendix
chapter.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Brake the
Bleed brake line after installing the brake hose (see
Line Bleeding in the Brakes chapter).
Suspension
Front Fork Inspection
• Visually inspect the front fork for oil leakage, scoring or
scratches on the outer surface of the inner tubes [A].
• Holding the brake lever, pump the front fork down and up
manually to check for smooth operation.
If the fork shown damages or oil leak, replace the dam-
aged parts.
If the fork rattles, inspect the oil level or tightening torque.
NOTICE
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
Front Fork Oil Change

• Remove the number plate (see Number Plate Removal in
the Frame chapter).
• Loosen the front fork clamp bolts (upper) [A].
• unit (right front
Loosen the cylinder unit (left front fork) [B]/spring adjuster
fork) using the top plug wrench [C].
Special Tool - Top Plug Wrench, 50 mm: 57001-1645
• Remove the front forks (see Front Fork Removal in the
Suspension chapter).
• Thoroughly clean the fork before disassembly.
NOTICE
Be careful not scratch the inner tube and not to
damage the dust seal.
Avoid scratching or damaging the inner tube or the
dust seal. Use a mild detergent and sponge out dirt
with plenty of water.
• Measure the length [A] between the top surface of the axle
holder [B] and under surface of the outer tube [C].
○Record the length before disassembling the fork.
Length
Standard: 314 ±2 mm (12.4 ±0.08 in.)
Left Front Fork

•Record the position of each damping adjuster [A] and then
turn [B] them to the softest position.
• Unscrew
tube [B].
the left front fork cylinder unit [A] from the outer
Special Tool - Top Plug Wrench, 50 mm [C]: 57001-1645

• Slowly slide down the outer tube.
• Hold the left front fork tube [A] upside down over a clean
container [B] and drain the oil.
NOTE
○Pump the outer tube up and down to discharge the fork
oil.
• Temporarily install the left front fork cylinder unit [A] to the
outer tube [B].
•○Hold the axle holder part [A] with a vise [B].

Protect the axle holder part with a soft jaws [C] or heavy
cloth when using a vise.
WARNING
If the axle holder is not securely clamped, the front
fork assembly may come out of the vise when com-
pressed, which could cause an accident resulting
in injury. However, clamping the axle holder too
tightly can damage it which will affect riding stabil-
ity. Use protective aluminum covers on the jaws of
the vise and do not tighten the vise excessively.
• Unscrew the adjuster assembly [D] completely.

NOTICE
When removing the adjuster assembly, do not force
to unscrew it at once using an impact wrench.
• Compress the outer tube by hands and remove the ad-

juster assembly from the axle holder part so that the lock-
nut appear about 20 ∼ 30 mm (0.79 ∼ 1.2 in.).
• Hold the locknut [A] with a wrench [B] and remove the left
front fork adjuster assembly [C].
NOTE
○Do not remove the locknut from the piston rod. The
piston rod may slide into the inner tube.
NOTICE
When loosening the locknut, the threads of the axle
holder do not touch the push rod. If the push rod is
scratched, it is possible to the damage in the cylin-
der unit.
• Remove the push rod [A].

NOTICE
Removing the locknut and pushing the piston rod
thread into the left front fork cylinder unit will dam-
age the oil seal. Do not remove the locknut from the
piston rod.
• Remove the fork leg from the vise.

• tube [B]. the left front fork cylinder unit [A] from the outer
Unscrew
• Remove
tube [B].
the left front fork cylinder unit [A] from the outer
• Holding the top plug wrench [A] with a vise, unscrew the
left front fork base valve assembly [B] on the fork cylinder
unit [C].
○Use a box wrench [D].
• Pull out the left front fork base valve assembly [A] from
the fork cylinder unit [B].
○Slowly compress the piston rod until it stops so that the
left front fork base valve assembly can be removed easily.
NOTICE
Be careful not to damage the bushing of the left
front fork base valve assembly.
Disassembling the left front fork base valve assem-
bly can lead to trouble. Do not disassemble the left
front fork base valve assembly.
• Hold the left front fork cylinder unit [A] upside down over
a clean container [B] and drain the oil.
NOTE
○Pump the piston rod up and down to discharge the fork
oil.
• Hold the front fork at the inverted position for more than
20 minutes to allow the fork oil to fully drain.
• Clean the threads [A] of the left front fork cylinder unit and
left front fork base valve assembly.
• Hold the left front fork cylinder unit [A] upright with the
piston rod fully stretched.
• Plug the oil hole [B] on the left front fork cylinder unit with
finger.
• Pour the specified oil.
Suspension Oil - SS-19 (1 L) : 44091-0009
Cylinder Unit Oil Amount
Standard: 330 mL (11.16 US oz.)
• Apply
rod.
specified fork oil to the sliding surface of the piston
• Purge the air from the fork cylinder [A] by gently moving
[B] the piston rod up and down several times.
• With the piston rod fully stretched, check the oil level in
the left front fork cylinder unit.
○Measure the oil level [A] from the top surface [B] in the left
front fork cylinder unit using a suitable gauge.
Fork Cylinder Unit Oil Level
Standard: 115 ∼ 123 mm (4.53 ∼ 4.84 in.)
NOTE
○Fork oil level may also be measured using the fork oil
level gauge.
Special Tool - Fork Oil Level Gauge: 57001-1290
• Replace the O-rings [A] on the left front fork base valve
assembly with new ones.
• Apply specified fork oil to the O-rings and bushings [B].
NOTICE
Do not damage the bushings when assembling the
left front fork base valve.
• With the piston rod [A] appear about 20 mm (0.79 in.) [B]
from fully compressed, gently install the left front fork base
valve assembly [C] slowly to the left front fork cylinder unit
[D].
NOTE
○Plug the oil hole [E] on the left front fork cylinder unit
with finger.
○While pulling the piston rod, install the base valve as-
sembly slowly and pushing down it fully.
○If there is difficulty in assembling the base valve, it may
be because the oil level is too high. Check the oil level
in the left front fork cylinder unit.
• Hold the top plug wrench [A] with a vise.

• wrench.
Hold the left front fork cylinder unit [B] with the top plug

• Tighten the left front fork base valve assembly [C].
Torque - Left Front Fork Base Valve Assembly: 30 N·m (3.1
kgf·m, 22 ft·lb)
• Turn the locknut fully in.

• Protectspecified
Apply fork oil to the piston rod sliding surface.
• thread damage. rod end with a heavy cloth [A] to prevent
the piston
• Hold
tion.
the left front fork cylinder unit [B] at the upright posi-
• Slowly pump the piston rod [C] several times about 100
mm (3.94 in.) [D].
NOTICE
Take care not to bent or damage the piston rod.
• Discharge the extra oil off the left front fork cylinder unit
[A] by pumping the piston rod [B] to full stroke [C].
NOTICE
Service carefully because oil flies out from the oil
hole of the left front fork cylinder unit.
• Check
est.
the compression damping force setting to the soft-
• Check the piston rod sliding surface for damage.

• hole [A]. extra oil from the left front fork cylinder unit oil
Drain the
• Blow out the extra oil from the oil hole of the left front fork
cylinder unit with the compressed air [B] blow to the oil
hole.
• Wipe the oil off completely from the cylinder unit.
NOTE
○If you cannot use compressed air, remove the air pres-
sure relief screw of the left front fork base valve assem-
bly. Upside down the fork damper for 10 minutes and
drain the oil from the left front fork cylinder unit.
• Protect
damage.
the piston rod end with a heavy cloth to prevent
•○Check the piston rod for smooth operation.

Pump the piston rod [A] to full stroke [B] by pushing down
the left front fork cylinder unit [C].
If the piston rod operation is not smooth, check the piston
rod for bend or damage.
• Hold the fork cylinder unit on level ground [A] while piston
rod is full stroked by your hand.
• Release the piston rod, then check that the piston rod
extends to maximum [B].
If the piston rod does not extend to maximum, bleed the
left front fork cylinder unit again.
NOTICE
Take care not to bend or damage the piston rod.
• Wipe the fork oil off completely from the left front fork cylin-
der unit [A].
• Compress the piston rod [B] to 200 ∼ 250 mm (7.87 ∼ 9.84
in.) [C] and hold the left front fork cylinder unit upright
position for 10 minutes.
• There should be no oil leak from the base valve assembly

part [A] or bottom of the cylinder [B].
If oil leaks from the base valve assembly part or bottom
of the cylinder, replace the cylinder unit.
• Hold the left front fork cylinder unit on level ground.
• Release the piston rod, then check that the piston rod
extends to maximum.
• Tighten the locknut [A] fully so that the piston rod thread
protrudes 10 ∼ 12 mm (0.39 ∼ 0.47 in.) [B].
• Wipe the fork oil off completely from the left front fork cylin-
der unit [A].
• Install the left front fork cylinder unit into the fork.
• Temporarily tighten the left front fork cylinder unit using

the top plug wrench.
•○Hold the axle holder part with a vise.

Protect the axle holder part with a soft jaws or heavy cloth
when using a vise.
WARNING
• Replace the left front fork adjuster assembly O-ring [A]

with a new one and apply specified fork oil to it.
• Insert the push rod [B] into the piston rod [C].
• Install
rod.
the left front fork adjuster assembly [D] to the push
• Slowly turn the left front fork adjuster assembly [A] clock-
wise until resistance is felt.
• Check the clearance between the locknut [B] and left front
fork adjuster assembly for more than 1 mm (0.04 in.) [C].
• Turn the locknut [A] counterclockwise until it contacts with

the left front fork adjuster assembly [B].
• With the locknut held immovable using a wrench [C],
tighten the left front fork adjuster assembly locknut.
Torque - Left Front Fork Adjuster Assembly Locknut: 22
N·m (2.2 kgf·m, 16 ft·lb)
NOTICE
When tightening the locknut, the threads of the axle
der unit.
• Apply a non-permanent locking agent to the left front fork

adjuster assembly.
• Tighten:
Torque - Left Front Fork Adjuster Assembly: 69 N·m (7.0
kgf·m, 51 ft·lb)
•○Compare the length [A] at assembly and at disassembly.

There should be same length.
If the length at assembly is longer than at disassembly,
check the left front fork adjuster assembly and locknut
installation.
Axle Holder [B]
Outer Tube [C]
Length
Standard: 314 ±2 mm (12.4 ±0.08 in.)
NOTE
○Keep the length while tighten the left front fork cylinder
unit.
• Using the top plug wrench, unscrew the left front fork
cylinder unit from the outer tube [A].
• Pour the specified fork oil into the left front fork outer tube.
Outer Tube Oil Amount

Standard:
KX250ZD 320 ±2.5 mL (10.82 ±0.085 US oz.)
(EUR, BR) 300 ±2.5 mL (10.14
±0.085 US oz.)
KX250ZE ∼ 300 ±2.5 mL (10.14 ±0.085 US oz.)
Adjustable Range: 300 ∼ 340 mL (10.14 ∼ 11.50 US oz.)
• Replace the O-ring on the left front fork cylinder unit with
a new one and specified fork oil to the O-ring.
• Temporarily install the left front fork cylinder unit [A] to the
outer tube [B] using the top plug wrench [C].
Right Front Fork

•Unscrew the right front fork spring adjuster unit [A] from
the outer tube [B].
• Hold the right front fork tube [A] upside down over a clean
container [B] and drain the oil.
NOTE
○Pump the outer tube up and down to discharge the fork
oil.
• Temporarily install the right front fork spring adjuster unit

[A] to the outer tube [B].
• Record the position of spring preload adjuster [A] and then

turn [B] it to the hardest position.
• Holding the top plug wrench [A] with a vise, unscrew the
right front fork spring preload adjuster [B] on the spring
adjuster unit with a top plug wrench [C].
Special Tools - Top Plug Wrench, 50 mm: 57001-1645
Top Plug Wrench, 36 mm: 57001-1705
• Hold the front fork at the inverted position to allow the fork
oil to drain.
•○Hold the axle holder part [A] with a vise [B].

Protect the axle holder part with a soft jaws [C] or heavy
cloth when using a vise.
WARNING
• Unscrew the right front fork bottom plug [D] completely.

NOTICE
When removing the right front fork bottom plug,
do not force to unscrew it at once using an impact
wrench.
When not using the Fork Spring Compressor (Special
Tool: 57001-1771):
• Compress the outer tube by hands and install the top plug
wrench [A] between the axle holder bottom [B] and locknut
[C].
WARNING
The fork spring applies pressure to the adjuster as-
sembly and can eject the special tool with substan-
tial force if the tool is not properly and securely
placed. Be sure the tool is fully in place as shown
in the photo, and keep fingers away to avoid getting
them pinched between the tool, adjuster assembly
and axle holder.
• Hold the locknut [A] with a wrench [B] and remove the
right front fork bottom plug [C].
NOTE
NOTICE
der unit.
• Compress the outer tube by hands and remove the top

plug wrench.
When using the Fork Spring Compressor (Special Tool:
57001-1771):
• Set the fork spring compressor [A] and a suitable jack [B].
Special Tool - Fork Spring Compressor: 57001-1771
• Put the heavy cloth [A] on the fork spring compressor [B].
• the forkfront
Set the fork, with its upper side facing downward, on
spring compressor.
• Insert the holder bar [A] of the fork spring compressor

(special tool: 57001-1587) to the axle hole and secure it
with the holder [B] of the fork spring compressor (special
tool: 57001-1771).
Special Tools - Fork Spring Compressor: 57001-1587
Fork Spring Compressor: 57001-1771
• Compress the outer tube with a suitable jack while keep-

ing the front fork upright, and install the top plug wrench
[A] between the axle holder bottom [B] and locknut [C].
WARNING
and axle holder.
• Remove the front fork from the fork spring compressor

with care not to drop the top plug wrench, and hold the
axle holder with a vise.
NOTE
○Protect the axle holder with a soft jaws or heavy cloth
when using a vise.
WARNING
• Hold the locknut [A] with a wrench [B] and remove the
right front fork bottom plug [C].
NOTE
NOTICE
der unit.
• Reset the front fork on the fork spring compressor with

care not to drop the top plug wrench.
ing the front fork upright, and remove the top plug wrench.
• Remove the front fork from the fork spring compressor.
• Unscrew the right front fork spring adjuster unit [A] from
the outer tube [B].
• Remove the following parts from the outer tube.

Right Front Fork Spring Adjuster Unit [A]
Collar [B]
Spring Seat [C]
Fork Spring [D]
• Hold the front fork at the inverted position for more than
20 minutes to allow the fork oil to fully drain.
• Tighten the locknut [A] fully.
• Install the fork piston rod puller adapter [A] to the threads
on the fork piston rod puller [B].
Special Tools - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289
Fork Piston Rod Puller Adapter: 57001-1791
• Install the piston rod puller [A] to the threads on the piston
rod end [B].
• Install the following parts in the outer tube.

Fork Spring [A]
Spring Seat [B]
Collar [C]
Right Front Fork Spring Adjuster Unit [D]
• Temporarily install the right front fork spring adjuster unit

[A] to the outer tube [B].
Tool: 57001-1771):
• Hold the axle holder part with a vise.
○Protect the axle holder part with a soft jaws or heavy cloth
when using a vise.
WARNING
• Compress the outer tube by hands and install the top plug
wrench [A] between the axle holder bottom and locknut.
WARNING
and axle holder.
57001-1771):
• Set the fork spring compressor [A] and a suitable jack [B].
Special Tool - Fork Spring Compressor: 57001-1771
• Put the heavy cloth [A] on the fork spring compressor [B].
• the forkfront
Set the fork, with its upper side facing downward, on
spring compressor.
• Insert the holder bar [A] of the fork spring compressor

(special tool: 57001-1587) to the axle hole and secure it
with the holder [B] of the fork spring compressor (special
tool: 57001-1771).
Special Tools - Fork Spring Compressor: 57001-1587
Fork Spring Compressor: 57001-1771

ing the front fork upright, and install the top plug wrench
[A] between the axle holder bottom [B] and locknut [C].
WARNING
and axle holder.
• Remove the front fork from the fork spring compressor

with care not to drop the top plug wrench, and hold the
axle holder with a vise.
NOTE
○Protect the axle holder with a soft jaws or heavy cloth
when using a vise.
WARNING
• Remove the piston rod puller [A].

• Replace the O-ring [A] on the right front fork bottom plug
with a new one and apply specified fork oil to it.
• Slowly turn the right front fork bottom plug [A] clockwise
until resistance is felt. Check the clearance between the
locknut [B] and right front fork bottom plug for more than
1 mm (0.04 in.).
• Turn the locknut counterclockwise until it contacts with the
right front fork bottom plug.
• Hold the right front fork bottom plug with a wrench [C] and
tighten the locknut.
Torque - Right Front Fork Bottom Plug Locknut: 22 N·m
(2.2 kgf·m, 16 ft·lb)
NOTICE
When tightening the locknut, the threads of the axle
der unit.
Tool: 57001-1771):
the right front fork bottom plug [A].
• Compress the outer tube by hands and remove the top
plug wrench [B].

57001-1771):
• Reset the front fork on the fork spring compressor with
care not to drop the top plug wrench.
the right front fork bottom plug [A].
ing the front fork upright, and remove the top plug wrench
[B].
• Remove the front fork from the fork spring compressor.
•○Hold the axle holder part with a vise.

Protect the axle holder part with a soft jaws or heavy cloth
when using a vise.
WARNING
• Tighten the right front fork bottom plug [A].

Torque - Right Front Fork Bottom Plug: 69 N·m (7.0 kgf·m,
51 ft·lb)
• Unscrew the right front fork spring adjuster unit [A] from
the outer tube [B].
• Clean the threads [A] of the right front fork spring adjuster
unit and right front fork spring preload adjuster.
• Replace the O-ring [B] on the right front fork spring
preload adjuster [C] with a new one.
• Turn the right front fork spring preload adjuster counter-
clockwise to the softest position.
• Apply specified fork oil to the O-ring.
• Install the right front fork spring preload adjuster so that

the projections [A] align to the holes [B] on the right front
fork spring adjuster unit.
• Holding the top plug wrench [A] with a vise, tighten the
right front fork spring preload adjuster [B] on the right front
fork spring adjuster unit [C] with a top plug wrench [D].
Special Tools - Top Plug Wrench, 50 mm: 57001-1645
Top Plug Wrench, 36 mm: 57001-1705
Torque - Right Front Fork Spring Preload Adjuster: 30 N·m
(3.1 kgf·m, 22 ft·lb)
• Pour the specified fork oil [A] into the right front fork outer
tube [B].
Fork Oil Amount
Standard:
KX250ZD 235 ±2.5 mL (7.95 ±0.085 US oz.)
KX250ZE ∼ 223 ±2.5 mL (7.54 ±0.085 US oz.)
Adjustable Range:
KX250ZD 230 ~ 378 mL (7.78 ~ 12.78 US oz.)
KX250ZE ∼ 218 ~ 366 mL (7.37 ~ 12.37 US oz.)
• Replace the O-ring on the right front fork spring adjuster

unit with a new one.
• Apply specified fork oil to the O-ring.
• [A] to the outer
Temporarily install the right front fork spring adjuster unit
tube [B].
•○Compare the length at assembly and at disassembly.
There should be same length.
If the length at assembly is longer than at disassembly,
check the right front fork bottom plug and locknut instal-
lation.
Length
Standard: 314 ±2 mm (12.4 ±0.08 in.)
• Install the front forks to the motorcycle (see Front Fork

Installation in the Suspension chapter).
• Remove the front fork clamp bolts (upper).
• front fork) [A]/spring
After installing the front fork, tighten the cylinder unit (left
adjuster unit (right front fork).
Special Tool - Top Plug Wrench, 50 mm [B]: 57001-1645
The torque of left front fork cylinder unit and right front
fork spring adjuster unit are specified to 34 N·m (3.5 kgf·m,
25 ft·lb), however, when you use the top plug wrench [A],
reduce the torque to 90% of the specified value [31 N·m (3.1
kgf·m, 23 ft·lb)] due to the distance [B] between the center
of the square hole, where the torque wrench is fitted, and
that of the octagonal hole of the wrench.
This torque value [31 N·m (3.1 kgf·m, 23 ft·lb)] is appli-
cable when you use a torque wrench whose length gives
leverage of approximately 310 mm (12.2 in.) between the
grip point to the center of the coupling square.
○Apply a non-permanent locking agent to the threads of
the front fork clamp bolts (upper).
Torque - Left Front Fork Cylinder Unit: 34 N·m (3.5 kgf·m,
25 ft·lb)
Right Front Fork Spring Adjuster Unit: 34 N·m (3.5
kgf·m, 25 ft·lb)
Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 15 ft·lb)
Rear Shock Absorber Oil Change
The oil should be changed in the rear shock absorber at
least once per racing season. The frequency for best per-
formance must be based upon riding conditions and rider
ability.
The disassembly procedure is included in the oil change
procedure.
Disassembly for Oil Change
• Remove the rear shock absorber (see Rear Shock Ab-
sorber Removal in the Suspension chapter).
• Remove the shock absorber spring (see Spring Replace-
ment in the Suspension chapter).
• Insert a suitable tool to center [A] of the reservoir cap, and

release the nitrogen gas completely (keep the suitable
tool inserted).
○For instructions on how to use the tool, follow the opera-
tion manual provided by the manufacturer.
WARNING
The shock contains high-pressure nitrogen gas that
when suddenly released can eject oil and internal
shock parts at high velocity, causing serious injury.
To avoid injury, do not point a suitable tool toward
your face or body when releasing nitrogen gas pres-
sure since an oil mist is often released with the ni-
trogen. Always release nitrogen gas pressure be-
fore disassembling the rear shock absorber to pre-
vent explosive separation of parts.
• Adjust the gas reservoir damping adjusters [A] to the soft-

est position.
• Remove the adjuster assembly [B] and pump the rear
shock to drain the oil.
• Using the hand press, push the reservoir cap [A].

• Circlip [B]
Remove:
Reservoir Cap
• Tap [A] the hole [B] in the stopper [C] with suitable tools
[D] to free the stopper from the rear shock body.
• Slide up the stopper of the piston rod, then lightly tap

around the seal with a suitable rod and mallet, and push
the seal assembly [A] 10 mm (0.39 in.) down.
• Remove the circlip [A].

• Wrap a heavy cloth around the rear shock body and piston
rod to prevent the oil diffusion.
• Lightly move the piston rod [B] back and forth, and pull
out the piston rod assembly.
• Drain the remains oil.
• Visually inspect the piston [A], O-ring [B], and oil seal as-
sembly [C].
If the piston, O-ring and oil seal assembly are badly
scored, rusty or damaged, replace them.
Piston Rod Assembly Disassembly/Assembly

If necessary, disassembly and assembly the piston rod
assembly as follows.
• Using the grinder, shave off the stake portions [A] of the
piston rod.
• Hold the lower of the piston rod assembly in a vise with

soft jaws or heavy cloth.
• Remove the locknut [A] and discard it.
NOTICE
Do not tighten the rebound damping adjuster of the
piston rod.
• Remove the piston rod assembly from the vise.

•○Remove the piston assembly [A].
Be careful not to disassemble it.
○Stick a suitable rod into the piston assembly and leave it
until being reinstalled.
• Inspect the slide bushing [A].

If the bushing is damaged, replace it.
○Cut the slide bushing.
• Replace the O-rings [B] with new ones.
• Install the O-rings and a new bushing on the piston.
• Wrap the threads [A] of the piston rod with tape.

• Remove the oil seal assembly [B].
• Remove the O-ring [A] and spring [B].
• Remove the rebound rubber [A] out of its groove [B].

• Collar [C]
Remove:
Spring Holder [D]

Oil Seal [E]
• Remove:
Oil Seal [A]
NOTICE
To avoid damage to the surfaces of the oil seal as-
sembly body [B], cover the screwdriver [C] with the
cloth [D].
• Replace the following with new ones.

Oil Seals
Rebound Rubber (if damaged)
O-ring
• Install each parts direction as shown.
Oil Seal [A]
Oil Seal [B]
Spring Holder [C]
Collar [D]
Rebound Rubber [E]
Spring [F]
O-ring [G]
• Remove:
Stopper [A]
Damper [B]
Damper Holder [C]
• Inspect the piston rod sliding surface [A].

If the sliding surface is scratches or distortion, replace it.
• Hold the lower of the piston rod assembly in a vise with

soft jaws or heavy cloth.
• Make the threads of the piston rod end using the die [A].
Die: 12 × 1.25 mm
• Clean
air.
all parts with solvent and dry them with compressed
• Install:
Damper Holder [A]
Damper [B]
Stopper [C]
• Wrap the threads of the piston rod with tape [A].

• Apply thin coat of rear shock oil to the sliding surface of
the piston rod.
• Insert the oil seal assembly [B].
• Remove the tape from piston rod.

• stopper [B]piston
Install the assembly [A] so that the thick side of the
faces downward.
NOTE
○Be careful not to change the original positions.
• Install the new piston rod locknut [C].
• Tighten:
Torque - Piston Rod Locknut: 37 N·m (3.8 kgf·m, 27 ft·lb)
• Stake the end of the piston rod with the chisel [A] in three
place [B].
• Check the oil seal assembly moving smoothly on the rod.
Assembly for Oil Change

•Check that the bladder [A] on the gas reservoir cap is not
partially collapsed.
If it is, push down the valve core with a screwdriver.
•Check the bladder for sign of damage or crack.
If necessary, replace it with a new one.
NOTICE
Do not use a damaged or partially collapsed blad-
der, because it may burst, gently reducing rear
shock performance.
• Replace the gas reservoir cap [B] with a new one.

• reservoir cap. to the lip [C] of the bladder and install the
Apply grease
• Push the bladder into the gas reservoir slowly until it just
clears the circlip groove. Wipe out any spilled oil.
• Replace the circlip with a new one.
WARNING
Pressurized nitrogen gas can explode out of the
shock reservoir cap if a weakened, deformed or
flawed circlip is used, allowing oil and internal parts
to burst out of the reservoir with great force and
cause serious injury. To avoid injury, always use a
new circlip whenever the shock is reassembled.
• Mount the circlip in the groove in the gas reservoir.

• Pull up the gas reservoir cap [A] against the circlip.

2.6 mm (0.1 in.) [B]
WARNING
Pressurized nitrogen gas can explode out of the
shock reservoir cap if the circlip is not properly in-
stalled, allowing oil and internal parts to burst out of
the reservoir with great force and cause serious in-
jury. To avoid injury, be sure to install a new circlip
in the proper position. If the end of the gas reservoir
cap and the end of the gas reservoir are not aligned,
the circlip is not correctly fitted in the groove in the
gas reservoir or the circlip is deformed and should
be replaced with a new one.
• Hold the upper portion of the rear shock absorber in a vise

with soft jaws or heavy cloth.
• Apply shock absorber oil to the bushing and O-ring of the

piston rod assembly.
• Insert the piston end [A] of the piston rod assembly into
the rear shock body [B] slowly. Do not insert the seal
assembly [C] yet.
• Push the seal assembly into the rear shock body until it
just clears the circlip groove.
• Fit
[B].
the circlip [A] into the groove in the rear shock body
• Pull up the piston rod assembly [C] against the circlip.

NOTICE
If the circlip is not a certain fit in the groove in the
rear shock body, the piston rod assembly may come
out of the shock absorber when injecting the nitro-
gen gas or riding the motorcycle.
• Force the stopper [A] into the rear shock body by lightly
tapping around the edge of the stopper with a plastic mal-
let.
• Fully extend the piston rod assembly.
• Remount the upper portion of the shock absorber in a vise

with soft jaws or heavy cloth.
• Fill the specified oil [A] into the damping adjuster assem-
bly hole.
Rear Shock Absorber Oil Amount
Standard: approx. 380 mL (12.8 US oz.)
• Purge the air from between the gas reservoir [A] and rear
shock body [B] by slowly pumping the piston rod [C] in
and out.
• Add the specified oil up to the damping adjuster assembly

hole neck [A].
NOTE
○Hold the adjuster assembly hole facing up and turn the
shock absorber to bleed the air from the reservoir com-
pletely.
• Fully extend the piston rod assembly.

• Inject the nitrogen gas to a pressure of 50 kPa (0.5
kgf/cm², 7 psi) through the valve on the gas reservoir.
• Check the rear shock body and gas reservoir for oil and
gas leaks.
If there are leaks, reassemble the related parts.
• Replace the O-rings [A] with new ones and apply shock
absorber oil.
• Install
slowly.
the gas reservoir damping adjuster assembly [B]
• Tighten:
Torque - Gas Reservoir Damping Adjuster Assembly: 29.5
N·m (3.01 kgf·m, 21.8 ft·lb)
• Wipe
rod.
off all oil from the shock absorber body and piston
• Inject the nitrogen gas up to the 980 kPa (10.0 kgf/cm²,

142 psi) pressure.
WARNING
High pressure gas is dangerous and can explode,
causing serious injury. To avoid injury, have a qual-
ified mechanic pressurize the shock reservoir with
nitrogen gas only. Do not use air or other gases,
since they may cause premature wear, rust, fire haz-
ard or substandard performance.
• Install the spring (see Rear Shock Absorber Spring Re-

placement).
• Install the rear shock absorber (see Rear Shock Absorber
Installation in the Suspension chapter).
• Adjust the spring preload (see Spring Preload Adjustment
in the Suspension chapter).
Swingarm and Uni-Trak Linkage Inspection
• Check the uni-trak component parts for wear periodically,
or whenever excessive play is suspected.
• Using the jack under the frame, raise the rear wheel off
the ground.
• Pump the seat down and up [A] 4 or 5 times, and inspect

the smooth stroke.
If the uni-trak linkage does not smooth stroke or noise is
found, inspect the uni-trak linkage bearings.
• Push and pull on the swingarm [A] to check for wear.

A small amount of play on the swingarm is normal and no
corrective action is needed. However, if excessive play is
felt, remove the uni-trak parts from the frame and check
for wear.
Swingarm and Uni-Trak Linkage Pivot Lubrication

• Refer to the Swingarm Bearing Installation and Rocker
Arm Bearing Installation in the Suspension chapter.
Steering
Steering Inspection
• Using the jack, raise the front wheel off the ground.
• With the front wheel pointing straight ahead, alternately
nudge each end of the handlebars.
○The front wheel should swing fully to left and right from
the force of gravity until the fork hits the stop.
If the steering binds or catches before the stop, check the
routing of the cables, hoses, and harnesses.
If the steering feels tight, adjust or lubricate the steering.
• Feel for steering looseness by pushing and pulling [A] the

forks.
If you feel looseness, adjust the steering.
Steering Adjustment
• Using the jack, raise the front wheel off the ground.
• Remove:
Number Plate [A] (see Number Plate Removal in the
Frame chapter)
Handlebar Pad [B]
• Disconnect:
Fuel Tank Breather Hose [C]
• Remove:
Handlebar Clamp Bolts [A]
Handlebar Clamps [B]
Handlebars [C]
• Loosen
sides.
the front fork clamp bolts (upper) [A] on both
• Remove the steering stem head nut [B] and washer [C].
• Remove the steering stem head [D].
• Turn the steering stem nut [A] with the steering stem nut
wrench [B] to obtain the proper adjustment.
If the steering is too tight, loosen the stem nut a fraction of
a turn; if the steering is too loose, tighten the nut a fraction
of a turn.
Special Tool - Steering Stem Nut Wrench: 57001-1100
NOTE
○Turn the nut 1/8 turn at a time maximum.
• Install the steering stem head and washer.

• clamp abolts
Apply non-permanent locking agent to the front fork
(upper).
• Tighten:
Torque - Steering Stem Head Nut: 98 N·m (10.0 kgf·m, 72
ft·lb)
Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 15 ft·lb)
NOTE
○Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
• Check the steering again.

If the steering is too tight or too loose, repeat the adjust-
ment as mentioned above.
Steering Stem Bearing Lubrication
• Remove the steering stem (see Steering Stem, Stem
Bearing Removal in the Steering chapter).
• Using a high flash-point solvent, wash the upper and
lower tapered rollers in the cages, and wipe the upper
and lower outer races, which are press-fitted into the
frame head pipe, clean off grease and dirt.
• Visually inspect the outer races and rollers.
Replace the bearing assemblies if they show wear or
damage.
• Pack the upper and lower tapered roller bearings [A] in
the cages with grease, and apply a light coat of grease to
the upper and lower outer races.
• Install the steering stem (see Steering Stem, Stem Bear-
ing Installation in the Steering chapter).
• Adjust the steering (see Steering Adjustment).
Frame
Frame Inspection
• Clean the frame with steam cleaner.
• Visually inspect the frame and rear frame for cracks,
dents, bending, or warp.
If there is any damage to the frame, replace it.
WARNING
A repaired frame may fail in use, possibly causing
an accident resulting in injury or death. If the frame
is bent, dented, cracked, or warped, replace it.
Electrical System
Spark Plug Cleaning and Inspection
• Remove the ignition coil (see Ignition Coil Removal in the
Electrical System chapter).
• Clean the plug hole, using the compressed air [A].
• Remove the spark plug [A] using a suitable 16 mm (0.63

in.) plug wrench [B].
• The plug may also be cleaned using a high flash-point
solvent and a nonmetal brush (nylon etc.).
If the spark plug electrodes are corroded or damaged,
or if the insulator is cracked, replace the plug. Use the
standard spark plug.
• Measure the gap [A] with a wire-type thickness gauge.

If the gap is incorrect, carefully bend the side electrode
[B] with a suitable tool to obtain the correct gap.
Spark Plug Gap
Standard: 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)
• Insert the spark plug into the suitable 16 mm (0.63 in.)

plug wrench, and finger-tighten it first.
• Tighten:
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)
• Install the ignition coil (see Ignition Coil Installation in the
Spark Plug Replacement
• Refer to the Spark Plug Cleaning and Inspection.
General Lubrication and Cable Inspection
Lubrication
• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri-
cation.
Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper End
Brake Lever Pivot Bolt
Clutch Lever Pivot Bolt
Brake Pedal Bolt
Cables: Lubricate with Rust Inhibitor.

Throttle Inner Cables
Clutch Inner Cable
Pivots: Lubricate with engine oil.

Rear Master Cylinder Joint Pin
Cable Inspection
• With the cable disconnected at the both ends, the cable
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Nut, Bolt, and Fastener Tightness Inspection

Tightness Inspection
• Check the tightness of the bolts and nuts listed here in
accordance with the Periodic Maintenance Chart. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the spec-
ified torque following the specified tightening sequence.
Refer to the Torque and Locking Agent section in this
chapter for torque specifications. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Nut, Bolt and Fastener to be checked
Wheels:
Spoke Nipples
Front Axle Nut
Front Axle Clamp Bolts
Rear Axle Nut Cotter Pin
Rear Axle Nut
Final Drive:
Chain Adjuster Locknut
Rear Sprocket Nuts
Brakes:
Front Master Cylinder Clamp Bolts
Brake Lever Pivot Bolt Locknut
Front Caliper Mounting Bolts
Brake Pedal Bolt
Rear Master Cylinder Push Rod Cotter Pin
Rear Master Cylinder Mounting Bolts
Rear Caliper Holder Shaft
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Mounting Nuts
Swingarm Pivot Shaft Nut
Uni-Trak Link Nuts
Steering:
Steering Stem Head Nut
Handlebar Clamp Bolts
Engine:
Throttle Cable Adjuster Locknut
Engine Mounting Bolts, Nuts
Engine Bracket Bolts, Nuts
Shift Pedal Bolt
Muffler Mounting Bolts
Exhaust Pipe Holder Nuts
Muffler Pipe Clamp Bolt
Clutch Cable Adjuster Locknut
Clutch Lever Pivot Bolt Locknut
Kick Pedal Bolt
Others:
Footpeg Cotter Pins
Rear Frame Mounting Bolts
Front Fender Bolts
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI)

Table of Contents
Exploded View........................................................................................................................ 3-4
DFI System............................................................................................................................. 3-8
DFI Parts Location.................................................................................................................. 3-13
Specifications ......................................................................................................................... 3-15 3
Special Tools and Sealant ...................................................................................................... 3-17
DFI Servicing Precautions ...................................................................................................... 3-18
DFI Servicing Precautions ................................................................................................... 3-18
Troubleshooting the DFI System ............................................................................................ 3-19
Outline............................................................................................................................... 3-19
Inquiries to Rider.................................................................................................................. 3-22
DFI System Troubleshooting Guide ....................................................................................... 3-24
Self-Diagnosis ........................................................................................................................ 3-28
Self-diagnosis Outline ....................................................................................................... 3-28
Self-diagnosis Procedures ................................................................................................ 3-28
How to Read Service Codes............................................................................................. 3-31
How to Erase Service Codes ............................................................................................ 3-31
Service Code Table........................................................................................................... 3-32
Backups ............................................................................................................................ 3-33
Throttle Sensor (Service Code 11) ......................................................................................... 3-35
Throttle Sensor Replacement ........................................................................................... 3-35
Throttle Sensor Input Voltage Inspection .......................................................................... 3-37
Throttle Sensor Output Voltage Inspection ....................................................................... 3-38
Throttle Sensor Resistance Inspection ............................................................................. 3-39
Intake Air Pressure Sensor (Service Code 12)....................................................................... 3-41
Intake Air Pressure Sensor Removal................................................................................ 3-41
Intake Air Pressure Sensor Installation............................................................................. 3-41
Intake Air Pressure Sensor Input Voltage Inspection........................................................ 3-42
Intake Air Pressure Sensor Output Voltage Inspection..................................................... 3-43
Intake Air Temperature Sensor (Service Code 13)................................................................. 3-47
Intake Air Temperature Sensor Removal/Installation........................................................ 3-47
Intake Air Temperature Sensor Output Voltage Inspection ............................................... 3-47
Intake Air Temperature Sensor Resistance Inspection ..................................................... 3-48
Water Temperature Sensor (Service Code 14) ...................................................................... 3-50
Water Temperature Sensor Removal/Installation ............................................................. 3-50
Water Temperature Sensor Output Voltage Inspection..................................................... 3-50
Water Temperature Sensor Inspection ............................................................................. 3-51
Crankshaft Sensor (Service Code 21).................................................................................... 3-53
Crankshaft Sensor Removal/Installation........................................................................... 3-53
Crankshaft Sensor Resistance Inspection ........................................................................ 3-53
Crankshaft Sensor Peak Voltage Inspection..................................................................... 3-53
Gear Position Switch (Service Code 25) ................................................................................ 3-54
Gear Position Switch Removal ......................................................................................... 3-54
Gear Position Switch Installation ...................................................................................... 3-54
Gear Position Switch Inspection ....................................................................................... 3-55
Vehicle-down Sensor (Service Code 31)................................................................................ 3-56
Vehicle-down Sensor Removal ......................................................................................... 3-56
Vehicle-down Sensor Installation ...................................................................................... 3-56
Vehicle-down Sensor Input Voltage Inspection................................................................. 3-56
Vehicle-down Sensor Output Voltage Inspection .............................................................. 3-57
Downstream Injector (Service Code 41)................................................................................. 3-59
3-2 FUEL SYSTEM (DFI)
Downstream Injector Removal.......................................................................................... 3-59

Downstream Injector Installation....................................................................................... 3-59
Downstream Injector Audible Inspection........................................................................... 3-60
Downstream Injector Resistance Inspection..................................................................... 3-60
Downstream Injector Power Supply Voltage Inspection ................................................... 3-61
Downstream Injector Output Voltage Inspection............................................................... 3-62
Downstream Fuel Line Inspection..................................................................................... 3-63
Upstream Injector (Service Code 42) ..................................................................................... 3-65
Upstream Injector Removal .............................................................................................. 3-65
Upstream Injector Installation ........................................................................................... 3-65
Upstream Injector Resistance Inspection ......................................................................... 3-66
Upstream Injector Power Supply Voltage Inspection ........................................................ 3-67
Upstream Injector Output Voltage Inspection ................................................................... 3-68
Upstream Injector Fuel Line Inspection ............................................................................ 3-69
Fuel Pump (Service Code 46) ................................................................................................ 3-71
Fuel Pump Removal ......................................................................................................... 3-71
Fuel Pump Installation ...................................................................................................... 3-71
Fuel Pump Operation Inspection ...................................................................................... 3-72
Fuel Pump Operating Voltage Inspection ......................................................................... 3-72
Pressure Regulator Removal............................................................................................ 3-73
Fuel Filter Cleaning........................................................................................................... 3-73
Ignition Coil (Service Code 51)............................................................................................... 3-75
Ignition Coil Removal/Installation...................................................................................... 3-75
Ignition Coil Primary Peak Voltage Inspection .................................................................. 3-75
Orange FI Warning Indicator Light (LED) (KX250ZE ∼) ......................................................... 3-76
Orange FI Warning Indicator Light (LED) Inspection ........................................................ 3-76
ECU ........................................................................................................................................ 3-78
ECU Identification ............................................................................................................. 3-78
ECU Removal ................................................................................................................... 3-78
ECU Installation ................................................................................................................ 3-79
ECU Power Supply Inspection.......................................................................................... 3-79
Fuel Line................................................................................................................................. 3-82
Fuel Pressure Inspection .................................................................................................. 3-82
Fuel Flow Rate Inspection ................................................................................................ 3-83
Throttle Grip and Cable .......................................................................................................... 3-85
Throttle Grip (Throttle Cable) Free Play Inspection .......................................................... 3-85
Throttle Grip (Throttle Cable) Free Play Adjustment......................................................... 3-85
Throttle Cable Replacement ............................................................................................. 3-85
Throttle Cable Lubrication................................................................................................. 3-86
Throttle Cable Inspection .................................................................................................. 3-86
Throttle Body Assy ................................................................................................................. 3-87
Idle Speed Inspection ....................................................................................................... 3-87
Throttle Bore Cleaning ...................................................................................................... 3-87
Throttle Body Assy Removal............................................................................................. 3-87
Throttle Body Assy Installation.......................................................................................... 3-87
Throttle Body Assy Disassembly ...................................................................................... 3-88
Throttle Body Assy Assembly ........................................................................................... 3-88
Air Cleaner.............................................................................................................................. 3-89
Air Cleaner Housing Removal........................................................................................... 3-89
Air Cleaner Housing Installation........................................................................................ 3-89
Element Removal/Installation ........................................................................................... 3-89
Element Cleaning and Inspection ..................................................................................... 3-89
Fuel Tank ................................................................................................................................ 3-90
Fuel Tank Removal ........................................................................................................... 3-90
Fuel Tank Installation ........................................................................................................ 3-92
Fuel Tank Cleaning ........................................................................................................... 3-93
This page intentionally left blank.

Exploded View
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Throttle Pulley Cover Bolts 3.4 0.35 30 in·lb
2 Throttle Cable Bolts 3.0 0.31 27 in·lb
3 Throttle Case Mounting Screws 3.8 0.39 34 in·lb
4 Air Cleaner Duct Clamp Bolt 2.0 0.20 18 in·lb
5 Delivery Joint Bolt 3.5 0.36 31 in·lb L
Intake Air Temperature Sensor Bolts
6 – – – L
(KX250ZF)
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
O: Apply high-quality foam air filter oil.
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Water Temperature Sensor 12 1.2 106 in·lb
2 Gear Position Switch Screws 2.9 0.30 26 in·lb L
AD: Apply adhesive.
G: Apply grease.
DFI System
DFI System
DFI System
1. Fuel Tank
2. Pressure Regulator
3. Fuel Pump
4. Intake Air Pressure Sensor
5. Downstream Injector
6. Upstream Injector
7. Intake Air Temperature Sensor
8. Air Cleaner Housing
9. Ignition Coil
10. Vehicle-down Sensor
11. Crankshaft Sensor
12. Throttle Sensor
13. Water Temperature Sensor
14. Gear Position Switch
15. ECU
16. Capacitor
17. Air Flow
18. Fuel Flow
DFI System
DFI System Wiring Diagram
DFI System
Part Names
1. ECU
2. Self-diagnosis Terminal
3. Throttle Sensor
9. Frame Ground 1
10. Ignition Coil
11. Spark Plug
12. Frame Ground 2
13. Fuel Pump
16. Capacitor
18. Engine Stop Switch
19. Orange FI Warning Indicator Light (LED) [KX250ZD]
Orange Launch Control Mode/FI Warning Indicator Light (LED) [KX250ZE ∼]
20. Not Used (KX250ZD)
Launch Control Mode Button (KX250ZE ∼)
21. FI Warning Indicator Light Assy (Option) [KX250ZD]
22. Kawasaki Diagnostic System Connector
○Color Codes:
BK: Black GY: Gray PU: Purple
BL: Blue LB: Light Blue R: Red
BR: Brown LG: Light Green V: Violet
CH: Chocolate O: Orange W: White
DG: Dark Green P: Pink Y: Yellow
G: Green
DFI System
Terminal Numbers of ECU Connectors
Terminal Names
1. Power Supply to ECU: R/W 19. Intake Air Temperature Sensor: LB
2. Unused 20. Unused
3. DFI Setting Data Selection 1: W/BL 21. Water Temperature Sensor: W
4. Downstream Injector: BL/R 22. Ground for ECU: BK/Y
5. Unused 23. Crankshaft Sensor (–): W/Y
6. Ground for ECU: BK/Y 24. Crankshaft Sensor (+): G/W
7. Orange FI Warning Indicator Light (LED) 25. Unused
[KX250ZD]: BL/W 26. External Communication Line (*KDS): P
Orange Launch Control Mode/FI Warning 27. Intake Air Pressure Sensor: BL
Indicator Light (LED) [KX250ZE ∼]: BL/W 28. Gear Position Switch: G/R
8. Upstream Injector: BL/BK 29. DFI Setting Data Selection 2: W/R
9. Unused 30. Engine Stop Switch: BK
10. Fuel Pump: P/BK 31. Unused (KX250ZD)
11. Ignition Coil: O Launch Control Mode Button (KX250ZE ∼):
12. Power Supply to Sensors: R/Y G
13. External Communication Line: Y/R 32. Self-diagnosis Terminal: Y
14. External Communication Line: Y/BK 33. Ground for Control System: BK/W
15. Throttle Sensor: Y/G *: KDS (Kawasaki Diagnostic System)
16. Vehicle-down Sensor: BR
17. Ground for Sensors: GY
18. Unused
DFI Parts Location
Kawasaki Diagnostic System Connector [A]
ECU [B]
FI Warning Indicator Light Harness Connector [C]
(KX250ZD)
Self-diagnosis Terminal [D]
Orange Launch Control Mode/FI Warning Indicator Light

(LED) [A] (KX250ZE ∼)
Vehicle-down Sensor [A]

Ignition Coil [B]
Intake Air Pressure Sensor [A]

Downstream Injector [B]
Upstream Injector [A]

DFI Parts Location
Capacitor [A]
Throttle Sensor [B]
Water Temperature Sensor [C]
Gear Position Switch [D]
Crankshaft Sensor [E]
Intake Air Temperature Sensor [A]
Fuel Pump [A]

Specifications
Item Standard
Digital Fuel Injection System
Idle Speed 2 050 ±50 r/min (rpm)
Throttle Body Assy:
Throttle Valve Single throttle valve
Bore 43 mm (1.69 in.)
ECU:
Make KEIHIN
Type Digital memory type, with built in IC igniter, sealed with resin
Fuel Pressure 294 kPa (3.0 kgf/cm², 43 psi) with engine idling
Fuel Pump:
Type Wesco pump
Discharge 40 mL (1.4 US oz.) or more for 5 seconds
Dual Injectors:
Downstream Injector:
Type EAT291
Nozzle Type Fine atomizing type with 4 holes
Resistance About 11.7 ∼ 12.3 Ω at 20°C (68°F)
Upstream Injector:
Type EAT812
Nozzle Type Fine atomizing type with 4 holes
Resistance About 11.7 ∼ 12.3 Ω at 20°C (68°F)
Throttle Sensor:
Input Voltage DC 4.75 ∼ 5.25 V
Output Voltage DC 0.58 ∼ 0.62 V at idle throttle opening
DC 3.65 ∼ 3.85 V at full throttle opening (for reference)
Resistance 4 ∼ 6 kΩ
Intake Air Pressure Sensor:
Output Voltage DC 3.80 ∼ 4.20 V at standard atmospheric pressure (see text
for details)
Intake Air Temperature Sensor:
Output Voltage About DC 2.28 ∼ 3.43 V at intake air temperature 20°C (68°F)
Resistance 909 ∼ 1 363 Ω at 40°C (104°F)
124 ∼ 186 Ω at 100°C (212°F)
Water Temperature Sensor:
Output Voltage About DC 2.80 ∼ 2.97 V at water temperature 20°C (68°F)
Resistance see text
Gear Position Switch:
Resistance see text
Vehicle-down Sensor:
Detection Angle More than 55 ∼ 75° for each bank
Output Voltage With sensor tilted 55 ∼ 75° or more right or left: DC 3.7 ∼ 4.4 V
With sensor arrow mark pointed up: DC 0.4 ∼ 1.4 V
Specifications
Item Standard
Throttle Grip and Cables
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: Fuel Pressure Gauge Adapter:
57001-125 57001-1593
Fork Oil Level Gauge: Fuel Hose:

57001-1290 57001-1607
Vacuum Gauge: Measuring Adapter:

57001-1369 57001-1700
Filler Cap Driver: Liquid Gasket, TB1211:

57001-1454 56019-120
Needle Adapter Set:

57001-1457
DFI Servicing Precautions
DFI Servicing Precautions
There are a number of important precautions that should
be followed servicing the DFI system.
○Connect these connectors until they click [A].

○Never any of the DFI electrical connectors are discon-
nected. The ECU memorizes service codes.
○Do not spray water on the electrical parts, DFI parts, con-
nectors, leads and wiring.
○When any fuel hose is disconnected, do not start the en-
gine. The fuel pump will operate and fuel will spout from
the fuel hose.
○Do not operate the fuel pump if it is completely dry. This
is to prevent pump seizure.
○Before removing the fuel system parts, blow the outer sur-
faces of these parts clean with compressed air.
○When any fuel hose is disconnected, fuel may spout out
by residual pressure in the fuel line. Cover the hose joint
with a piece of clean cloth to prevent fuel spillage.
○When installing the fuel hoses, avoid sharp bending, kink-
ing, flattening or twisting, and run the fuel hoses with a
minimum of bending so that the fuel flow will not be ob-
structed.
○Run the hoses according to Cable, Wire, and Hose Rout-
ing section in the Appendix chapter.
○To prevent corrosion and deposits in the fuel system, do
not add to fuel any fuel antifreeze chemicals to fuel.
○If the motorcycle is not properly handled, the high pres-

sure inside the fuel line can cause fuel to leak or the hose
to burst. Remove the fuel tank (see Fuel Tank Removal)
and check the fuel hoses [A].
Replace the fuel hose if any fraying, cracks or bulges are
noticed.
○To maintain the correct fuel/air mixture (F/A), there must

be no intake air leaks in the DFI system. Be sure to install
the oil filler plug [A] after filling the engine oil.
Torque - Oil Filler Plug: 3.5 N·m (0.36 kgf·m, 31 in·lb)
Troubleshooting the DFI System
Outline
KX250ZD
When an abnormality in the system occurs, the condition
of the problem is stored in the memory of the ECU (Elec-
tronic Control Unit). With the engine stopped and conduct
a self-diagnosis inspection, the service code is indicated by
the number of times the orange FI warning indicator light
(LED) (option) blinks.
Ask the rider about the conditions [A] under which the
problem occurred and try to determine the cause [B].
KX250ZE ∼
When an abnormality in the system occurs, the orange FI
warning indicator light (LED) goes on to alert the rider. In
addition, the condition of the problem is stored in the mem-
ory of the ECU (Electronic Control Unit). With the engine
stopped and turned in the self-diagnosis mode, the ser-
vice code is indicated by the number of times the orange
FI warning indicator light (LED) blinks.
When due to a malfunction, the orange FI warning indica-
tor light (LED) remains lit, ask the rider about the conditions
under which the problem occurred and try to determine the
cause.
• First, conduct a self-diagnosis inspection and then a non
-self-diagnosis inspection. The non-self-diagnosis items
are not indicated by the orange FI warning indicator light
(LED). Don’t rely solely on the DFI self-diagnosis function,
use common sense.
If the orange FI warning indicator light (LED) goes on by
kicking the kick pedal about 10 times, these parts are bro-
ken.
Even when the DFI system is operating normally, the or-
ange FI warning indicator light (LED) may light up under
strong electrical interference. No repair needed.
When the orange FI warning indicator light (LED) goes on
and the motorcycle is brought in for repair, check the service
codes.
When the repair has been done, the light doesn’t go on.
But the service codes stored in memory are not erased to
preserve the problem history, and the light can display the
codes in the self-diagnosis mode. The problem history is
referred when solving unstable problems.
Much of the DFI system troubleshooting work consists
of confirming continuity of the wiring. The DFI parts are
assembled and adjusted with precision, and it is impossible
to disassemble or repair them.
• When checking the DFI parts, use a digital meter which

can be read two decimal place voltage or resistance.
○The DFI part connectors [A] have seals [B], including the
ECU. When measuring the input or output voltage with the
connector joined, use the needle adapter set [C]. Insert
the needle adapter inside the seal until the needle adapter
reaches the terminal.
Special Tool - Needle Adapter Set: 57001-1457
NOTICE
Insert the needle adapter straight along the terminal
in the connector to prevent short-circuit between
terminals.
• Make sure that measuring points are correct in the con-

nector, noting the position of the lock [D] and the lead
color before measurement. Do not reverse connections
of a digital meter.
• Be careful not to short-circuit the leads of the DFI or elec-
trical system parts by contact between adapters.
• Connect the power supply harness (option P/No. 26011
-0246) and the battery to the capacitor lead connector,
and measure the voltage with the connector joined.
NOTICE
Incorrect, reverse connection or short circuit by
needle adapters could damage the DFI or electrical
system parts.
○After measurement, remove the needle adapters and ap-

ply sealant to the seals [A] of the connector [B] for water-
proofing.
Sealant - Liquid Gasket, TB1211: 56019-120
• Always check the connected battery condition before re-

placing the DFI parts. A fully charged battery is a must
for conducting accurate tests of the DFI system.
• Trouble may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the problem. If the problem was caused by
some other item or items, they too must be repaired or
replaced, or the new replacement part will soon fail again.
• Measure coil winding resistance when the DFI part is cold
(at room temperature).
• Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, short,
etc. Deteriorated leads and bad connections can cause
reappearance of problems and unstable operation of the
DFI system.
If any wiring is deteriorated, replace the wiring.
• Pull each connectors [A] apart and inspect it for corrosion,

dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it. Connect them securely.
•Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect a digital meter between the ends of the leads.
○Set the digital meter, and read the digital meter.
If the digital meter does not read 0 Ω, the lead is defective.
Replace the lead or the main harness.
○If both ends of a harness [A] are far apart, ground [B] the
one end [C], using a jumper lead [D] and check the con-
tinuity between the end [E] and the ground [F]. This en-
ables to check a long harness for continuity. If the harness
is open, repair or replace the harness.
○When checking a harness [A] for short circuit, open one

end [B] and check the continuity between the other end
[C] and ground [D]. If there is continuity, the harness has
a short circuit to ground, and it must be repaired or re-
placed.
• Narrow down suspicious locations by repeating the con-

tinuity tests from the ECU connectors.
If no abnormality is found in the wiring or connectors, the
DFI parts are the next likely suspects. Check the part,
starting with input and output voltages. However, there is
no way to check the ECU itself.
If an abnormality is found, replace the affected DFI part.
If no abnormality is found in the wiring, connectors, and
DFI parts, replace the ECU.
DFI Diagnosis Flow Chart
Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms
the rider has encountered.
○Try to find out exactly what problem occurred under exactly what conditions by asking the rider;
knowing this information may help you reproduce the problem.
○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will
help you decide if it is a DFI system problem, or a general engine problem.
Sample Diagnosis Sheet
Rider name Model
Engine No. Frame No.
Date problem occurred
Environment when problem occurred.
Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other:
Temperature □ hot, □ warm, □ cold, □ very cold, □ always
Problem
frequency
□ chronic, □ often, □ once
Altitude □ normal, □ high (about 1 000 m or more)
Motorcycle conditions when problem occurred.
Orange FI □ lights up immediately after starting the engine, and goes off after 2 seconds
warning (with engine running) (normal).
indicator □ lights up for 2 seconds immediately after starting the engine, and goes off for 3
light (LED) seconds, and then keeps going on. (with engine running) (DFI problem)
(Option)*
□ unlights (light, ECU or its wiring fault).
□ sometimes lights up (probably wiring fault).
Starting □ no cranking. □ no spark.
difficulty □ no fuel flow (□ no fuel in tank, □ no fuel pump sound).
□ engine flooded (do not crank engine with throttle opened, which promotes
engine flooding).
□ other:
Engine stops □ right after starting. □ when moving off.
□ when opening throttle grip. □ when stopping the motorcycle.
□ when closing throttle grip. □ when cruising.
□ other:
Poor running □ very low fast idle speed.
at low speed □ very low idle speed, □ very high idle speed, □ rough idle speed.
□ spark plug loose (tighten it).
□ spark plug dirty, broken, or gap maladjusted (adjust it).
□ backfiring. □ afterfiring.
□ hesitation when acceleration. □ engine oil viscosity too high.
□ brake dragging. □ clutch slipping.
□ engine overheating.
□ other:
Poor running □ spark plug loose (tighten it). □ spark plug incorrect (replace it).
or no power at □ spark plug dirty, broken, or gap maladjusted (remedy it).
high speed
knocking (fuel poor quality or
□ incorrect).
□ engine overheating.
□ brake dragging. □ engine oil level too high.
□ clutch slipping. □ engine oil viscosity too high.
□ other:
*: KX250ZD
DFI System Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant
simply as a rough guide to assist the troubleshooting for some of the more common difficulties in
DFI system.
○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and
circuits are checked out good, be sure to check the ECU for ground and power supply. If the
ground and power supply are checked good, replace the ECU.
Engine Won’t Turn Over

Symptoms or Possible Causes Actions (chapter)
Gear position switch trouble Inspect (see chapter 3).
Vehicle-down sensor OFF Reinstall (see chapter 3).
Crankshaft sensor trouble Inspect (see chapter 16).
Ignition coil shorted or not in good contact Inspect or Reinstall (see chapter 16).
Ignition coil trouble Inspect (see chapter 16).
Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2).
Spark plug incorrect Replace it with correct plug (see chapter 2).
ECU ground and power supply trouble Inspect (see chapter 3).
ECU trouble Inspect (see chapter 3, 16).
No or little fuel in tank Supply fuel (see Owner’s Manual).
Upstream/downstream injector trouble Inspect and replace (see chapter 3).
Fuel pump not operating Inspect (see chapter 3).
Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3).
Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see
chapter 3).
Fuel line clogged Inspect and repair (see chapter 3).
Poor Running at Low Speed

Spark weak:
Fuel/air mixture incorrect:
Little fuel in tank Supply fuel (see Owner’s Manual).
Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3).
Air cleaner duct loose Reinstall (see chapter 3).
Throttle body assy holder loose Reinstall (see chapter 3).
Upstream/downstream injector dust seal damage Replace (see chapter 3).
Upstream/downstream injector O-ring damage Replace (see chapter 3).
chapter 3).
Intake air pressure sensor trouble Inspect (see chapter 3).

Water temperature sensor trouble Inspect (see chapter 3).
Intake air temperature sensor trouble Inspect (see chapter 3).
Throttle sensor trouble Inspect (see chapter 3).
Unstable (rough) idling:
Fuel pressure too low or too high Inspect (see chapter 3).
Upstream/downstream injector trouble Inspect (see chapter 3).
Engine stalls easily:
Fuel pump trouble Inspect (see chapter 3).
Fuel pressure too low or too high Inspect (see chapter 3).
chapter 3).
Poor acceleration:
Fuel pressure too low Inspect (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Stumble:

Surge:
Unstable fuel pressure Fuel pressure regulator trouble (Inspect and
replace fuel pump) or kinked fuel line (Inspect
and replace fuel pump) (see chapter 3).
Backfiring when deceleration:
After fire:
Spark plug burned or gap maladjusted Replace (see chapter 16).
Other:
Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight,
and examine leads for signs of burning or fraying
(see chapter 3).
Poor Running or No Power at High Speed

Firing incorrect:
Fuel/air mixture incorrect:
Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3).
Air cleaner housing loose Reinstall (see chapter 3).
Throttle body assy holder loose Reinstall (see chapter 3).
Upstream/downstream injector dust seal damage Replace (see chapter 3).
Water or foreign matter in fuel Change fuel. Inspect and clean fuel system (see
chapter 3).
Upstream/downstream injector O-ring damage Replace (see chapter 3).
Upstream/downstream injector clogged Inspect and repair (see chapter 3).

Knocking:
Fuel poor quality or incorrect Fuel change (Use the gasoline recommended in
the Owner’s Manual).
Miscellaneous:
Throttle valve will not fully open Inspect throttle cables and lever linkage (see
chapter 3).
Engine overheating - Water temperature sensor (see Overheating of Troubleshooting Guide in
or crankshaft sensor trouble chapter 17)
Exhaust Smokes Excessively:
(Black smokes)
Air cleaner element clogged Clean element (see chapter 3).
Fuel pressure too high Inspect (see chapter 3).
(Brown smoke)
Air cleaner housing loose Reinstall (see chapter 3).
Self-Diagnosis
Self-diagnosis Outline
The self-diagnosis system has three modes and can be
switched to another mode by grounding the self-diagnosis
terminal.
User Mode
The ECU connected orange FI warning indicator light
(LED) (option)* goes on when DFI system and ignition
system parts are faulty. In case of serious troubles, the
ECU stops the injection/ignition operation.
*: KX250ZD
Dealer Mode 1
The orange FI warning indicator light (LED) emits service
code(s) to show the problem(s) which the DFI system, and
ignition system has at the moment of diagnosis.
Dealer Mode 2
The orange FI warning indicator light (LED) emits service
code(s) to show the problem(s) which the DFI system, and
ignition system had in the past.
Self-diagnosis Procedures
• Disconnect the connector [A] (KX250ZD).
• Connect the FI warning indicator light assy (option) [A]

(KX250ZD).
• Disconnect the capacitor lead connector [A].

Self-Diagnosis

-0246) [A] to the capacitor lead connector [B] of the main
harness.
-0246) to the 12 V battery [C].
• The orange FI warning indicator light (LED) will go on for
2 seconds for bulb inspection when the ECU activates.
If the orange FI warning indicator light (LED) does not go
on, inspect the harness or replace the FI warning indicator
light assy.
NOTE
○Use a fully charged battery when conducting
self-diagnosis. Otherwise, the light blinks very slowly
or doesn’t blink.
• Disconnect the self-diagnosis connector [A] and connect

an auxiliary lead [B] for grounding to the self-diagnosis
terminal [C].
NOTE
○Keep the self-diagnosis terminal grounded during self
-diagnosis.
• To enter the self-diagnosis dealer mode 1, ground the self

-diagnosis terminal [A] for more than 2 seconds [B], and
then keep it grounded continuously [C].
Ground [D]
Open [E]
•Count the blinks of the light to read the service code.
○Keep the lead ground until you finish reading the service
code.
• To enter the self-diagnosis dealer mode 2, ground the

self-diagnosis terminal [A] and open it, and then ground
the self-diagnosis terminal more than 3 times within 3 sec-
onds [B], and then keep it grounded continuously [C].
Ground [D]
Open [E]
•Count the blinks of the light to read the service code.
○Keep the lead ground until you finish reading the service
code.
Self-Diagnosis
Self-Diagnosis Flow Chart
Self-Diagnosis
How to Read Service Codes
○Service codes are shown by a series of long and short blinks of the orange FI warning indicator light
(LED) as shown below.
○Read 10th digit and unit digit as the orange FI warning indicator light (LED) blinks.
○When there are a number of problems, all the service codes can be stored and the display will
begin starting from the lowest number service code in the numerical order. Then after completing
all codes, the display is repeated until the self-diagnosis terminal is open. When the self-diagnosis
terminal is opened, the orange FI warning indicator light (LED) will go on in one second.
○If there is no problem no code and the orange FI warning indicator light (LED) blinks with cycle of
0.5 seconds.
○For example, if two problems occurred in the order of 21, 12, the service codes are displayed from
the lowest number in the order listed.
(12 → 21) → (12 → 21) → · · · (repeated)
○If the problem is with the following parts, the ECU cannot memorize these problems, the orange FI
warning indicator light (LED) doesn’t go on, and no service codes can be displayed.
ECU Power Source Wiring and Ground Wiring (see ECU Power Supply Inspection)
How to Erase Service Codes

○Even if the battery or the ECU are disconnected, or the problem is solved, all service codes remain
in the ECU.
○In this model, the problem history cannot be erased. However, the past service code can be erased
using the KDS 3 version kit.
Self-Diagnosis
Service Code Table
Service Orange FI Warning Indicator
Problems
Codes Light (LED)
11 Throttle sensor malfunction, wiring open or short
Intake air pressure sensor malfunction, wiring
12
open or short
Intake air temperature sensor malfunction, wiring
13
open or short
Water temperature sensor malfunction, wiring
14
open or short
Crankshaft sensor malfunction, wiring open or
21
short
Gear position switch malfunction, wiring open
25
or short
Vehicle-down sensor, malfunction, wiring open
31
or short
Downstream injector malfunction, wiring open
41
or short
Upstream injector malfunction, wiring open or

42
short
46 Fuel pump malfunction, wiring open or short
51 Ignition coil malfunction, wiring open or short

Notes:
○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure
to check the ECU for ground and power supply. If the ground and power supply are checked good,
replace the ECU.
○When no service code is displayed, the electrical parts of the DFI system has no fault, and the
mechanical parts of the DFI system and the engine are suspect.
Self-Diagnosis
Backups
○The ECU takes the following measures to prevent engine damage when the DFI or the ignition
system parts have troubles.
Service Output Signal Usable
Parts Backups by ECU
Codes Range or Criteria
If the throttle sensor system fails (the signal is
out of the usable range, wiring short or open),
the ECU locks ignition timing into the ignition
Throttle Sensor Output timing at closed throttle position and sets the
11 Throttle Sensor Voltage DFI in the D-J method (1).
0.58 ∼ 3.85 V Also, the throttle sensor system and intake
air pressure fails, the ECU locks ignition
timing into the ignition timing at closed throttle
position and sets the DFI in the α-N method.
If the intake air pressure sensor system fails
(the signal Pv is out of the usable range, wiring
Intake Air Intake Air Pressure
short or open), the ECU sets the DFI in the
12 Pressure (Absolute)
α-N method.
Sensor Pv = 20 ∼ 106.7 kPa
Conduct ignition and injection operations
whenever crank rotates by 360 degrees.
Intake Air
Intake Air Temperature
13 Temperature ECU sets Ta at 26°C.
–30 ∼ +120°C
Sensor
Water
Water Temperature
14 Temperature ECU sets Tw at 80°C.
–30 ∼ +120°C
Sensor
Crankshaft sensor must
Crankshaft send 18 signals (output If crankshaft sensor generates other than 18
21
Sensor signal) to the ECU at signals, the engine stops by itself.
the one cranking.
Gear Position Gear Position Switch If the gear position switch fails, set the low
25
Switch 0.469 ∼ 4.727 V gear position.
Vehicle-down Sensor If the vehicle-down sensor system has failures,
Vehicle-down
31 Output Voltage the ECU shuts off the fuel system and the
Sensor
0.4 ∼ 4.4 V ignition system. ECU does not backup.
If the downstream injector break down, wiring
Downstream In succession pulse is short or open, the ECU stops the signal out-
41
Injector output from ECU. put to both injectors and the fuel delivery is
stopped.
If the upstream injector break down, wiring
Upstream In succession pulse is short or open, the ECU stops the signal out-
42
Injector output from ECU. put to both injectors and the fuel delivery is
stopped.
Supply Voltage If the pump fails, wiring short or open, the ECU
46 Fuel Pump
6 ∼ 15 V stops the pump operations.
ECU sends signals
(output voltage) If the ignition coil fails, the ECU shuts off the
51 Ignition Coil
continuously to the signal to the ignition coil.
ignition coil.
Self-Diagnosis
Note:
(1) D-J Method and α-N Method: When the engine load is light like at idling or low speed, the ECU
determines the injection quantity by calculating from the throttle vacuum (intake air pressure sen-
sor output voltage) and engine speed (crankshaft sensor output voltage). This method is called
D-J method (low-speed mode). As the engine speed increases, and the engine load turns middle
to heavy, the ECU determines the injection quantity by calculating from the throttle opening (throt-
tle sensor output voltage) and the engine speed. This method is called α-N method (high-speed
mode).
Throttle Sensor (Service Code 11)
The throttle sensor is a rotating variable resistor that
change output voltage according to throttle operating.
The ECU senses this voltage change and determines fuel
injection quantity, and ignition timing according to engine
rpm, and throttle opening.
Input Terminal [A]
Output Terminal [B]
Ground Terminal [C]
Throttle Sensor Replacement

NOTICE
Never drop the throttle sensor [A], especially on a
hard surface. Such a shock to the throttle sensor
can damage it.
NOTE
○These procedures are explained on the assumption that
the intake and exhaust systems of the engine are in
good condition.
○When adjusting the throttle sensor, use a digital voltage
meter which can be read the third decimal place. The
DC voltage accuracy must be less than ±0.05% reading
and ±4 digits at DC 1 V.
○Read the manufacture’s instructions thoroughly before
using the meter, incorrect values may cause improper
adjustments.
• Remove the throttle body assy (see Throttle Body Assy

Removal).
• Check the paint on the stop screw [A] and make sure
that the stop screw has not been adjusted. If stop screw
has been adjusted, throttle body assy has to be replaced.
Don’t tamper with stop screw.
• Remove:
Throttle Sensor Screw [A]
Throttle Sensor [B]
• Replace:
Throttle Sensor Screw [A]
Throttle Sensor [B]
O-ring [C]
• Apply engine oil to the new O-ring, and install it to the new
throttle sensor.
• Engage
[B].
the inner rotor groove [A] with the throttle shaft
•○Insert the throttle sensor [A] into the throttle body.

Set the throttle sensor to the throttle body assy.
• Turn the throttle sensor counterclockwise [B] until the
mounting holes align.
• Tighten the throttle sensor screw lightly.
• Connect the measuring adapter [A] between the main har-

ness [B] and throttle sensor [C].
Special Tool - Measuring Adapter: 57001-1700
• Connect
leads.
a digital meter [D] to the measuring adapter
Throttle Sensor Output Voltage

Connections to Adapter:
Digital Meter (+) → W (sensor Y) lead
Digital Meter (–) → BK (sensor BK) lead
• Refer to the Self-diagnosis Procedures, connect the 12 V

battery to the main harness.
• Adjust the sensor position so that the output voltage is

within the specified voltage range.
Standard: DC 0.58 ∼ 0.62 V
If the input voltage reading shows other than 5 V, calculate
a valid output voltage range as follows:
Example:
In the case of an input voltage of 4.75 V
0.58 × 4.75 ÷ 5.00 = 0.55 V
0.62 × 4.75 ÷ 5.00 = 0.59 V
Thus, the valid range is 0.55 ∼ 0.59 V.
• Once the sensor is properly adjusted, tighten the throttle

sensor screw.
NOTE
○Take care not to vary the output voltage when tightening
the throttle sensor screw.
• Turn the throttle from closed to full open more than 2

times, and measure the output voltage.
If the output voltage is not within the specified range, read-
just the sensor.
• Install the throttle body assy (see Throttle Body Assy In-
stallation).
Throttle Sensor Input Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Rear Frame with Air Cleaner Housing (see Rear Frame
Removal in the Frame chapter)
• Disconnect the throttle sensor connector and connect the
measuring adapter [A] between these connectors.
Main Harness [B]
Throttle Sensor [C]
• Connect
leads.
Throttle Sensor Input Voltage

Digital Meter (+) → R (sensor BL) lead

• Measure the input voltage with the engine stopped and

with the connector joined.
Input Voltage
• Disconnect the power supply harness.

If the reading is within the standard, check the output volt-
age (see Throttle Sensor Output Voltage Inspection).
If the reading is out of the standard, remove the ECU and
check the wiring for continuity between the main harness
connectors.
○Disconnect the ECU and sensor connectors.
Wiring Continuity Inspection
ECU Connector [A] ←→
Throttle Sensor Connector [B]
R/Y lead [C] (ECU terminal 12) ←→ BL lead [D]
GY lead [E] (ECU terminal 17) ←→ BK lead [F]
If the wiring is good, check the ECU for its ground and
power supply (see ECU Power Supply Inspection).
If the ground and power supply are good, replace the ECU
(see ECU Removal/Installation).
Throttle Sensor Output Voltage Inspection
• Measure the throttle sensor output voltage in the same
way as input voltage inspection.
○Disconnect the throttle sensor connector and connect the
measuring adapter [A] between these connectors.
Main Harness [B]
Throttle Sensor [C]
Digital Meter [D]

Digital Meter (+) → W (sensor Y) lead

• correct.the idle speed to ensure the throttle opening is
Check
Idle Speed
Standard: 2 050 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it
(see Idle Speed Adjustment in the Periodic Maintenance
chapter).

• Measure the output voltage with the engine stopped, and
Output Voltage
Standard: DC 0.58 ∼ 0.62 V at idle throttle opening
DC 3.65 ∼ 3.85 V at full throttle opening (for
reference)
NOTE
○Open the throttle, confirm the output voltage will be rise.
○The standard voltage refers to the value when the volt-
age reading at the Input Voltage Inspection shows 5 V
exactly.
○When the input voltage reading shows other than 5 V,
derive a voltage range as follows.
Example:
In the case of a input voltage of 4.75 V.
0.58 × 4.75 ÷ 5.00 = 0.55 V
0.62 × 4.75 ÷ 5.00 = 0.59 V
Thus, the valid range is 0.55 ∼ 0.59 V

If the reading is out of the standard, check the throttle sen-
sor resistance (see Throttle Sensor Resistance Inspec-
tion).
If the reading is within the standard, remove the ECU and
connectors.
Throttle Sensor Connector [B]
Y/G lead [C] (ECU terminal 15)
GY lead [D] (ECU terminal 17) ←→ BK lead [E]
Throttle Sensor Resistance Inspection
• Disconnect the throttle sensor connector.
• [B].
Connect a digital meter [A] to the throttle sensor connector
• Measure the throttle sensor resistance.

Throttle Sensor Resistance
Connections:
BL lead [C] ← → BK lead [D]
Standard: 4 ∼ 6 kΩ
If the reading is out of the standard, replace the throttle
sensor (see Throttle Sensor Replacement).
If the reading is within the standard, but the problem still
exists, replace the ECU (see ECU Removal/Installation).
Throttle Sensor Circuit
1. ECU
2. Throttle Sensor
Intake Air Pressure Sensor (Service Code 12)
Intake Air Pressure Sensor Removal
NOTICE
Never drop the intake air pressure sensor, espe-
cially on a hard surface. Such a shock to the sensor
can damage it.
• Remove:
Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic
Maintenance chapter)
Intake Air Pressure Sensor Connector [A]
• Slide the rubber damper [B] to outside and remove it with
the intake air pressure sensor [C] from the plate [D].
• Remove the vacuum hose [A] from the throttle body assy.
• damper [C]. intake air pressure sensor [B] from the rubber
Remove the
Intake Air Pressure Sensor Installation

• Assemble the rubber damper [A] to the intake air pressure
sensor [B].
○Fit the straight edges [C].
• Install the vacuum hose [A].

• Connect theintake
Install the air pressure sensor [B].
• intake air pressure sensor connector [C].
Intake Air Pressure Sensor Input Voltage
Inspection
NOTE
• Disconnect the intake air pressure sensor connector and
connect the measuring adapter [A] between these con-
nectors.
Main Harness [B]
Intake Air Pressure Sensor [C]
• Connect
leads.
Intake Air Pressure Sensor Input Voltage

Digital Meter (+) → R (sensor R/Y) lead
Digital Meter (–) → BK (sensor GY) lead

Input Voltage

age (see Intake Air Pressure Sensor Output Voltage In-
spection).
connectors.
Intake Air Pressure Sensor Connector [B]
R/Y lead [C] (ECU terminal 12)
GY lead [D] (ECU terminal 17)
Intake Air Pressure Sensor Output Voltage
Inspection
• Measure the intake air pressure sensor output voltage in
the same way as input voltage inspection.
○Disconnect the intake air pressure sensor connector and
nectors.
Main Harness [B]
Intake Air Pressure Sensor [C]
Digital Meter [D]

Digital Meter (+) → W (sensor BL) lead

• Measure the output voltage with the engine stopped and
Output Voltage
Usable Range: DC 3.80 ∼ 4.20 V at standard
atmospheric pressure (101.32 kPa, 76
cmHg)
NOTE
○The output voltage changes according to local atmo-
spheric pressure.

If the reading is out of the usable range, replace the sen-
sor.
If the reading is within the usable range, remove the ECU
and check the wiring for continuity between the main har-
ness connectors.
Intake Air Pressure Sensor Connector [B]
BL lead [C] (ECU terminal 27)
If the wiring is good, check the sensor for various vacuum.
•Remove the intake air pressure sensor [A] and disconnect
the vacuum hose from the sensor.
•Connect an auxiliary hose [B] to the intake air pressure
sensor.
•Temporarily install the intake air pressure sensor.
○Connect a digital meter [C], vacuum gauge [D], the fork oil
level gauge [E] and the measuring adapter to the intake
air pressure sensor.
Special Tools - Fork Oil Level Gauge: 57001-1290
Vacuum Gauge: 57001-1369
Measuring Adapter: 57001-1700

Digital Meter (+) → W (sensor BL) lead

• Measure the intake air pressure sensor output voltage
from various vacuum readings, while pulling the handle
of the fork oil level gauge.
•Check the intake air pressure sensor output voltage, us-
ing the following formula and chart.
Suppose:
Pg: Vacuum Pressure (Gauge) of Throttle Body
Pl: Local Atmospheric Pressure (Absolute) measured by
a barometer
Pv: Vacuum Pressure (Absolute) of Throttle Body
Vv: Sensor Output Voltage (V)
then
Pv = Pl – Pg
For example, suppose the following data is obtained:
Pg = 8 cmHg (Vacuum Gauge Reading)
Pl = 70 cmHg (Barometer Reading)
Vv = 3.2 V (Digital Meter Reading)
then
Pv = 70 – 8 = 62 cmHg (Absolute)
Plot this Pv (62 cmHg) at a point [1] on the chart and draw a
vertical line through the point. Then, you can get the usable
range [2] of the sensor output voltage.
Usable range = 3.08 ∼ 3.48 V
Plot Vv (3.2 V) on the vertical line. → Point [3].
Results: In the chart, Vv is within the usable range and
the sensor is normal.
If the reading is out of the usable range, replace the sen-
sor.
If the reading is within the usable range, check the ECU
for its ground and power supply (see ECU Power Supply
Inspection).
ID: Idling
Ps: Standard Atmospheric Pressure (Absolute)
Pv: Throttle Vacuum Pressure (Absolute)
ST: Standard of Sensor Output Voltage (V)
TO: Throttle Full Open
UR: Usable Range of Sensor Output Voltage (V)
Vv: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
Intake Air Pressure Sensor Circuit
1. ECU
Intake Air Temperature Sensor (Service Code 13)
Intake Air Temperature Sensor Removal/Instal-
lation
NOTICE
Never drop the intake air temperature sensor, espe-
can damage it.
• Remove the rear frame with air cleaner housing (see Rear
Frame Removal in the Frame chapter).
• Remove the bolts [A].

• Pull out the intake air temperature sensor [B].
• Put the intake air temperature sensor [A] into the air
cleaner housing.
○Face the locks [B] to left side.
• For KX250ZF, apply a non-permanent locking agent to the
intake air temperature sensor bolts.
• Tighten the bolts [C] securely.
Intake Air Temperature Sensor Output Voltage

Inspection
NOTE
• Disconnect the intake air temperature sensor connector
and connect the measuring adapter [A] between these
connectors.
Main Harness [B]
Intake Air Temperature Sensor [C]
• Connect
leads.
Intake Air Temperature Sensor Output Voltage

Digital Meter (+) → R (sensor LB) lead


the connector joined.
Output Voltage
Standard: About DC 2.28 ∼ 3.43 V at intake air
temperature 20°C (68°F)
NOTE
○The output voltage changes according to the intake air
temperature.

If the reading is within the standard, check the ECU for
its ground, and power supply (see ECU Power Supply
Inspection).
connectors.
Intake Air Temperature Sensor Connector [B]
LB lead [C] (ECU terminal 19)
If the wiring is good, check the intake air temperature sen-
sor resistance (see Intake Air Temperature Sensor Resis-
tance Inspection).
Intake Air Temperature Sensor Resistance
Inspection
• Remove the intake air temperature sensor (see Intake Air
Temperature Sensor Removal/Installation).
• Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion is submerged.
• Suspend a thermometer [B] with the heat-sensitive por-
tions [C] located in almost the same depth.
NOTE
○The sensor and thermometer must not touch the con-
tainer side or bottom.
• Place the container over a source of heat and gradually

raise the temperature of the oil while stirring the oil gently
for even temperature.
• Using a digital meter, measure the internal resistance of
the sensor.
Intake Air Temperature Sensor Resistance
Standard: 909 ∼ 1 363 Ω at 40°C (104°F)
124 ∼ 186 Ω at 100°C (212°F)
If the reading is out of the standard, replace the sensor.
Intake Air Temperature Sensor Circuit
1. ECU
Water Temperature Sensor (Service Code 14)
Water Temperature Sensor Removal/Installation
NOTICE
Never drop the water temperature sensor, espe-
can damage it.
• Drain the coolant (see Coolant Draining in the Cooling

System chapter).
• Remove:
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Connector [A]
Water Temperature Sensor [B]
• Replace the O-ring with a new one.
• Install the new O-ring to the water temperature sensor.
• Tighten:
Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 106
in·lb)
• Fill the engine with coolant and bleed the air from the
cooling system (see Coolant Filling in the Cooling System
chapter).
Water Temperature Sensor Output Voltage
Inspection
NOTE
• Disconnect the water temperature sensor connector and
nectors.
Main Harness [B]
Water Temperature Sensor [C]
• Connect
leads.
Water Temperature Sensor Output Voltage

Digital Meter (+) → R (sensor W) lead

the connector joined.
Output Voltage
Standard: About DC 2.80 ∼ 2.97 V at water temperature
20°C (68°F)
NOTE
○The output voltage changes according to the coolant
temperature in the engine.

its ground, and power supply (see ECU Power Supply
Inspection).
connectors.
Water Temperature Sensor Connector [B]
W lead [C] (ECU terminal 21)
If the wiring is good, check the water temperature sensor
resistance (see Water Temperature Sensor Inspection).
Water Temperature Sensor Inspection
• Remove the water temperature sensor (see Water Tem-
perature Sensor Removal/Installation).
• Suspend the sensor [A] in a container of machine oil so
that the heat-sensitive portion and threaded portion are
submerged.
• Suspend a thermometer [B] with heat-sensitive portions
[C] located in almost the same depth.
NOTE
○The sensor and thermometer must not touch the con-
tainer side or bottom.
• Place the container over a source of heat and gradually

raise the temperature of the oil while stirring the oil gently
for even temperature.
• Using a digital meter, measure the internal resistance of
the sensor.
Water Temperature Sensor Resistance
Temperature Resistance (kΩ)
−20°C (−4°F) *18.80 ±2.37
0°C (32°F) *(About 6.544)
40°C (104°F) 1.136 ±0.095
100°C (212°F) 0.1553 ±0.0070
*: Reference Information
If the measurement is out of the range, replace the sensor.
Water Temperature Sensor Circuit
1. ECU
Crankshaft Sensor (Service Code 21)
The crankshaft sensor has no power source, and when
the engine stops, the crankshaft sensor generates no sig-
nals.
Crankshaft Sensor Removal/Installation
• Refer to the Stator Coil Removal/Installation in the Elec-
trical System chapter.
Crankshaft Sensor Resistance Inspection
• Refer to the Crankshaft Sensor Inspection in the Electrical
System chapter.
If the reading is within the standard, check the peak volt-
age (see Crankshaft Sensor Peak Voltage Inspection).
Crankshaft Sensor Peak Voltage Inspection
• Refer to the Crankshaft Sensor Peak Voltage Inspection
in the Electrical System chapter.
connectors.
Crankshaft Sensor Connector [B]
G/W lead [C] (ECU terminal 24)
W/Y lead [D] (ECU terminal 23)
Crankshaft Sensor Circuit
1. ECU
Gear Position Switch (Service Code 25)
Gear Position Switch Removal
• Remove:
Left Radiator Shroud (see Radiator Shroud Removal in
the Frame chapter)
Shift Pedal (see Shift Pedal Removal in the Crank-
shaft/Transmission chapter)
Engine Sprocket Cover and Drive Chain Guide (see En-
gine Sprocket Removal in the Final Drive chapter)
Gear Position Switch Connector [A]
• Open the clamps [A].
• Remove:
Screws [A]
Gear Position Switch [B]
• Remove:
O-ring [A]
Gear Position Switch Fingers [B]
Springs
Gear Position Switch Installation

• Install the spring [A] on the switch finger [B].
• toward theswitch
Insert the finger so that the small diameter [C] is
shift drum.
• Replace
to it.
the O-ring [D] with a new one, and apply grease
• Clean the contact points on the position switch.

• switch screws.
Apply a non-permanent locking agent to the gear position
• Tighten:
Torque - Gear Position Switch Screws: 2.9 N·m (0.30 kgf·m,
26 in·lb)
Gear Position Switch (Service Code 25)
Gear Position Switch Inspection
NOTE
○Be sure the transmission mechanism is good condition.
• Remove the left radiator shroud (see Radiator Shroud Re-
• Disconnect the gear position switch lead connector [A].
• Set a digital meter [A] and connect it to the terminals in

the gear position switch lead connector [B] and ground.
Internal Circuit [C]
Gear Position Switch Resistance
Gear Connections
Position G/R Lead [D] - Ground BK Lead [E] - Ground
Neutral 1.43 ∼ 1.58 kΩ about 0 Ω
1st 2.23 ∼ 2.46 kΩ about 0 Ω
2nd 0.95 ∼ 1.06 kΩ about 0 Ω
3rd 644 ∼ 711 Ω about 0 Ω
4th 410 ∼ 453 Ω about 0 Ω
5th 241 ∼ 266 Ω about 0 Ω
If the digital meter reading is not as specified, replace the
gear position switch with a new one.
Gear Position Switch Circuit
1. ECU
3. Frame Ground 1
Vehicle-down Sensor (Service Code 31)
When the motorcycle is down, the engine stops according
to the condition of the below table.
Engine Speed Time Engine Condition
2 500 rpm or less After 30 seconds Stop
2 500 rpm or more After 3 seconds Stop
When the vehicle-down sensor is broken, the engine will
stop at 3 seconds after the engine starts.
Vehicle-down Sensor Removal
NOTICE
Never drop the vehicle-down sensor, especially on
a hard surface. Such a shock to the sensor can
damage it.
• Remove the fuel tank (see Fuel Tank Removal).

• Disconnect the connector
Pull the vehicle-down sensor [A] from the bracket.
• [B].
Vehicle-down Sensor Installation

• The UPPER mark [A] of the sensor should face upward
and install the sensor.
• Connect the connector.
WARNING
Incorrect installation of the vehicle-down sensor
could cause sudden loss of engine power. The
rider could lose balance during certain riding situ-
ations like leaning over in a turn with the potential
for an accident resulting in injury or death. Ensure
that the vehicle-down sensor is held in place by the
sensor bracket.
Vehicle-down Sensor Input Voltage Inspection
NOTE
• Disconnect the vehicle-down sensor connector and con-
nect the measuring adapter [A] between these connec-
tors.
Main Harness [B]
Vehicle-down Sensor [C]
• Connect
leads.
Vehicle-down Sensor Input Voltage

Digital Meter (+) → R (sensor R/Y) lead


Input Voltage
age (see Vehicle-down Sensor Output Voltage Inspec-
tion).
connectors.
Vehicle-down Sensor Connector [B]
R/Y lead [C] (ECU terminal 12)
Vehicle-down Sensor Output Voltage Inspection
• Remove the vehicle-down sensor, and connect the mea-
suring adapter [A].
Main Harness [B]
Vehicle-down Sensor [C]
• Connect a digital meter [D] to the measuring adapter
leads.
Vehicle-down Sensor Output Voltage
Digital Meter (+) → W (sensor BR) lead
• Hold the sensor vertically.

• batterytotothetheSelf-diagnosis
Refer
main harness.
Procedures, connect the 12 V
• with the connector joined.

Measure the output voltage with the engine stopped and
○Tilt the sensor 55 ∼ 75° or more [A] right or left, then hold
the sensor almost vertical with the arrow mark [B] pointed
up [C].
Output Voltage
Standard: With sensor tilted 55 ∼ 75° or more right
or left: DC 3.7 ∼ 4.4 V
With sensor arrow mark pointed up: DC
0.4 ∼ 1.4 V
If the reading is out of the standard, replace the sensor.
connectors.
Vehicle-down Sensor Connector [B]
BR lead [C] (ECU terminal 16)
Vehicle-down Sensor Circuit
1. ECU
Downstream Injector (Service Code 41)
NOTICE
Never drop the downstream injector, especially on
a hard surface. Such a shock to the downstream
injector can damage it.
Downstream Injector Removal

• Remove
Removal).
the throttle body assy (see Throttle Body Assy
• Remove the delivery pipe mounting screw [A].

• stream injector.
Remove the delivery pipe [B] together with the down-
NOTE
○Do not damage the insertion portions of the down-
stream injector when they are pulled out from the
throttle body.
• Separate
pipe [B].
the downstream injector [A] from the delivery
Downstream Injector Installation

• Replace the O-ring [A] and dust seal [B] with a new one.
• Apply engine oil to the O-ring and dust seal.
• Assemble
[B].
the delivery pipe [A] and downstream injector
• Fit the projections [A] on the delivery pipe to the hollows

[B] of the throttle body assy.
• Tighten the delivery pipe mounting screw [A].

Downstream Injector Audible Inspection

• Remove:
the Frame chapter)
•Start the engine, and let it idle.
•Apply the standard tip screwdriver [A] to the downstream
injector.
•Put the grip end into your ear, and listen whether the
downstream injector is clicking or not.
○A sound scope can also be used.
○The click interval becomes shorter as the engine speed
rises.
If the downstream injector click at a regular intervals, the
downstream injector is normal.
•Stop the engine.
If downstream injector does not click, check the down-
stream injector resistance (see Downstream Injector Re-
sistance Inspection).
Downstream Injector Resistance Inspection
• Remove:
Downstream Injector Connector [A]
• Connect a digital meter to the terminals in downstream

injector [A].
• Measure the downstream injector resistance.
Downstream Injector Resistance
Connections: R/W terminal ←→ BL/R terminal
Standard: About 11.7 ∼ 12.3 Ω at 20°C (68°F)

If the reading is out of the standard, replace the down-
stream injector.
If the reading is within the standard, check the power sup-
ply voltage (see Downstream Injector Power Supply Volt-
age Inspection).
Downstream Injector Power Supply Voltage
Inspection
NOTE
• Disconnect the downstream injector connector and con-
nect the measuring adapter [A] between these connec-
tors.
Main Harness [B]
Downstream Injector [C]
• Connect a digital meter [D] to the measuring adapter lead.
Downstream Injector Power Supply Voltage
Connections the Adapter:
Digital Meter (+) → R (Downstream Injector R/W) lead
Digital Meter (–) → Battery (–) Terminal

• Measure
stopped.
the power supply voltage with the engine
Power Supply Voltage

Standard: Battery Voltage
If the voltage is out of the standard, check the power sup-
ply wiring (see Downstream Injector Circuit).
If the reading is within the standard, check the output
voltage (see Downstream Injector Output Voltage Inspec-
tion).
Downstream Injector Output Voltage Inspection
NOTE
•○Remove the ECU (see ECU Removal).
Do not disconnect the ECU connector.
• Using the needle adapter set and connect a digital meter
[A] to the ECU connector [B].
Downstream Injector Output Voltage

Connections to ECU Connector:
Digital Meter (+) → BL/R lead (ECU terminal 4)
• Measure the output voltage with the engine stopped with

the connector jointed.
Output Voltage

its ground and power supply (see ECU Power Supply In-
spection).
connectors.
○Disconnect the ECU and downstream injector connector.
ECU Connector [A] ← → Downstream Injector
Connector [B]
BL/R lead [C] (ECU terminal 4)
If the wiring good, check the ECU ground and power sup-
ply (see ECU Power Supply Inspection).
If the ground and power supply good, replace the ECU
Downstream Fuel Line Inspection
• Remove:
○Place a piece of cloth around the fuel outlet pipe of fuel
pump and delivery pipe of throttle body assy.
•Check the downstream injector fuel line for leakage as
follows:
○Apply engine oil to the delivery pipe lightly.
○Connect a commercially available vacuum/pressure
pump [A] to the delivery pipe [B] with the fuel hose [C].
○Hold both ends with the clamps [D].
•Apply a soap and water solution to the areas [E].
•Watching the pressure gauge, squeeze the pump lever
[F], and build up the pressure until the pressure reaches
the maximum pressure.
Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm², 44 psi)
NOTICE
During pressure testing, do not exceed the maxi-
mum pressure for which the system is designed.
○Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once, or if bubbles are found in
the area, the fuel line is leaking. Replace the delivery pipe
assy, downstream injector and related parts.
○Repeat the leak test, and check the fuel line for no leak-
age.
• Install:
Fuel Tank (see Fuel Tank Installation)
• Start the engine, check the fuel leakage.
Downstream Injector Circuit
1. ECU
3. Frame Ground 1
4. Capacitor
Upstream Injector (Service Code 42)
NOTICE
Never drop the upstream injector, especially on a
hard surface. Such a shock to the upstream injector
can damage it.
Upstream Injector Removal

• Remove:
Rear Frame with Air Cleaner Housing (see Rear Frame
• Remove the delivery joint bolt [A].

• Remove
injector.
the delivery pipe [B] together with the upstream
• Separate
[B].
the upstream injector [A] from the delivery pipe
Upstream Injector Installation

• Replace the dust seal [A] and O-ring [B] with a new one.
• Assemble the delivery pipe [A] and upstream injector [B].

• Fit the projection [A] on the delivery pipe to the hollow [B]
of the air cleaner housing.
○Face the connector side to left side.

the delivery joint bolt [A].
• Tighten:
Torque - Delivery Joint Bolt: 3.5 N·m (0.36 kgf·m, 31 in·lb)
Upstream Injector Resistance Inspection

• Remove:
the Frame chapter)
Upstream Injector Connector [A]
• Connect a digital meter to the terminals in upstream in-

jector [A].
• Measure the upstream injector resistance.
Upstream Injector Resistance
Connections: R/W terminal ←→ BL/BK terminal
Standard: About 11.7 ∼ 12.3 Ω at 20°C (68°F)

If the reading is out of the standard, replace the upstream
injector.
If the reading is within the standard, check the power sup-
ply voltage (see Upstream Injector Power Supply Voltage
Inspection).
Upstream Injector Power Supply Voltage
Inspection
NOTE
• Disconnect the upstream injector connector and connect
the measuring adapter [A] between these connectors.
Main Harness [B]
Upstream Injector [C]
• Connect a digital meter [D] to the measuring adapter lead.
Upstream Injector Power Supply Voltage
Connections the Adapter:
Digital Meter (+) → R (Upstream Injector R/W) lead

• Measure
stopped.
the power supply voltage with the engine
Power Supply Voltage

If the voltage is out of the standard, check the power sup-
ply wiring (see Upstream Injector Circuit).
age (see Upstream Injector Output Voltage Inspection).
Upstream Injector Output Voltage Inspection
NOTE
•○Remove the ECU (see ECU Removal).
Do not disconnect the ECU connector.
• Using the needle adapter set and connect a digital meter
[A] to the ECU connector [B].
Upstream Injector Output Voltage

Connections to ECU Connector:
Digital Meter (+) → BL/BK lead (ECU terminal 8)
• Measure the output voltage with the engine stopped with

the connector jointed.
Output Voltage

its ground and power supply (see ECU Power Supply In-
spection).
connectors.
○Disconnect the ECU and upstream injector connector.
ECU Connector [A] ← → Upstream Injector Connector
[B]
BL/BK lead [C] (ECU terminal 8)
If the wiring good, check the ECU ground and power sup-
ply (see ECU Power Supply Inspection).
If the ground and power supply good, replace the ECU
•Install the removed parts (see appropriate chapters).
○Install the upstream injector connector boot so that notch
side faces inside.
Upstream Injector Fuel Line Inspection
• Remove:
Fuel Hose (see Rear Frame Removal in the Frame chap-
ter)
○Place a piece of cloth around the delivery pipe of air
cleaner housing.
•Check the upstream injector fuel line for leakage as fol-
lows:
○Apply engine oil to the delivery pipe lightly.
○Connect a commercially available vacuum/pressure
pump [A] to the delivery pipe [B] with the fuel hose [C].
○Hold both ends with the clamps [D].
•Apply a soap and water solution to the areas [E].
•Watching the pressure gauge, squeeze the pump lever
[F], and build up the pressure until the pressure reaches
the maximum pressure.
Fuel Line Maximum Pressure
Standard: 300 kPa (3.06 kgf/cm², 44 psi)
NOTICE
During pressure testing, do not exceed the maxi-
mum pressure for which the system is designed.
○Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good.
If the pressure drops at once, or if bubbles are found in
the area, the fuel line is leaking. Replace the delivery pipe
assy, upstream injector and related parts.
○Repeat the leak test, and check the fuel line for no leak-
age.
• Install:
Fuel Hose (see Rear Frame Installation in the Frame
chapter)
• Start the engine, check the fuel leakage.
Upstream Injector Circuit
1. ECU
3. Frame Ground 1
4. Capacitor
Fuel Pump (Service Code 46)
Fuel Pump Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Always stop the
engine and do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
NOTICE
Never drop the fuel pump, especially on a hard sur-
face. Such a shock to the pump can damage it.
• Draw the fuel out from the fuel tank with a commercially
available electric pump.
•○Remove the fuel tank (see Fuel Tank Removal).
Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug the fuel pipe
of the fuel tank.
• Turn the fuel tank upside down.

• looseningthesequence
Loosen fuel pump bolts evenly following the specified
[1 ∼ 5], and remove the fuel pump
[A].
NOTICE
Do not pull the leads of the fuel pump. If they are
pulled, the lead terminals may be damaged.
• Discard the fuel pump gasket [A].
Fuel Pump Installation

• Remove the dirt or dust from the fuel pump [A] by lightly
applying compressed air.
• Replace the fuel pump gasket with a new one.
• Install the fuel pump [A] to the fuel tank.

• the fuel pump
Apply a non-permanent locking agent to the threads of
bolts.
• specified tighteningthesequence
Gradually tighten fuel pump bolts evenly following the
[1 ∼ 6].
Fuel Pump Operation Inspection

NOTE
• Make sure that the fuel pump operates (make light
sounds) for 5 seconds, and then stops.
If the pump does not operate as described above, check
the operating voltage (see Fuel Pump Operating Voltage
Inspection).
Fuel Pump Operating Voltage Inspection
NOTE
• Remove the fuel tank bolt and band.
• Disconnect the
Lift the fuel tank and hold it.
• measuring adapterfuel pump lead connector and connect the
[A] between these connectors.
Main Harness [B]
Fuel Pump [C]
• Connect
leads.
Fuel Pump Operating Voltage

Digital Meter (+) → R (pump R) lead
Digital Meter (–) → BK (pump BK) lead

• Measure the operating voltage with engine stopped and

Operating Voltage
If the reading is not battery voltage, check the wiring for
continuity (see Fuel Pump Circuit).
If the reading is in specification, but the fuel pump does
not operate, replace the fuel pump (see Fuel Pump Re-
moval/Installation).
Pressure Regulator Removal
○The pressure regulator [A] is built into the fuel pump and
can not be removed.
Fuel Filter Cleaning

○The fuel filter [A] is built into the pump and can not be
cleaned or checked.
If the fuel filter is suspected of clogging or being damaged,
replace it with the fuel pump as a set.
Fuel Pump Circuit
1. ECU
2. Capacitor
3. Fuel Pump
4. Frame Ground 1
Ignition Coil (Service Code 51)
Ignition Coil Removal/Installation
• Refer to the Ignition Coil Removal/Installation in the Elec-
trical System chapter.
Ignition Coil Primary Peak Voltage Inspection
• Refer to the Ignition Coil Primary Peak Voltage Check in
the Electrical System chapter.
If the peak voltage is much lower than standard, check
the wiring for continuity (see Ignition Coil Circuit).
Ignition Coil Circuit
1. ECU
2. Capacitor
3. Frame Ground 1
4. Frame Ground 2
5. Ignition Coil
6. Spark Plug
Orange FI Warning Indicator Light (LED) (KX250ZE ∼)
Orange FI Warning Indicator Light (LED)
Inspection
NOTE
• Confirm that the orange FI warning indicator light (LED)
goes on for 2 seconds when the battery connected to the
main harness.
If the orange FI warning indicator light (LED) does not
go on, check the wiring for continuity between the main
harness.
○Disconnect the capacitor and the launch control mode
button connectors.
Capacitor Connector [A] ←→
Launch Control Mode Button Connector [B]
O/Y lead [C] ←→ R/W lead [D]
○Disconnect the ECU connector.

Launch Control Mode Button Connector [B]
BL/W lead (ECU Terminal 7) [C]
If the wiring is good, check the orange FI warning indicator
light (LED).
• Connect the 12 V battery [A] to the launch control mode

button connector [B] as shown in the figure.
If the orange FI warning indicator light (LED) does not go
on, replace the launch control mode button.
If the orange FI warning indicator light (LED) goes on,
check the ECU for its ground and power supply (see ECU
Power Supply Inspection).
Orange FI Warning Indicator Light (LED) (KX250ZE ∼)
Orange FI Warning Indicator Light (LED) Circuit
1. ECU
2. Orange FI Warning Indicator Light (LED)
3. Capacitor
4. Frame Ground 1
ECU
ECU Identification
○Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with
each other and use only the ECU for your model. Other-
wise, the motorcycle cannot clear the regulation.
ECU Identification (KX250ZD)
Part Number [A] Specification
21175-0782 US, CA
21175-0792 AU, EUR, TH
21175-0800 BR
ECU Identification (KX250ZE)

21175-0846 US, CA
21175-0847 AU, EUR, TH
21175-0848 BR
ECU Identification (KX250ZF)

21175-0918 US, CA
21175-0919 AU, EUR, TH
21175-0920 BR
ECU Removal
NOTICE
Never drop the ECU, especially on a hard surface.
Such a shock to the ECU can damage it.
• Remove:
Number Plate (see Number Plate Removal in the Frame
chapter)
Bolt [A]
Connector Bracket [B]
• Disconnect the ECU connector [A].

• Pull the ECU [B] together with rubber protector.
ECU
ECU Installation
• Install the ECU [A] to the rubber protector [B].
• Insert the slits [A] of the rubber protector to the ECU

bracket.
• Connect the ECU connector [B].
ECU Power Supply Inspection

• Remove the number plate (see Number Plate Removal in
the Frame chapter).
• Visually inspect the ECU connector.
If the connector is clogged with mud or dust, blow it off
with compressed air.
• Remove the ECU (see ECU Removal).
• Visually inspect the terminals [A] of the ECU connectors.
If the terminals of the main harness connector are dam-
aged, replace the main harness.
If the terminals of the ECU connector are damaged, re-
place the ECU.
• Disconnect the capacitor lead connector [A].

ECU
• Set a digital meter [A] and check the following wiring for
continuity.
ECU Grounding Inspection
Capacitor Connector [B] (BK/W lead) ←→
ECU Connector [C]
BK/Y lead [D] (ECU terminal 6)
BK/Y lead [E] (ECU terminal 22)
BK/W lead [F] (ECU terminal 33)
Criteria: 0 Ω
If no continuity, check the connector or main harness, and
repair or replace them if necessary.
If the wiring is good, check the power supply voltage of
the ECU.
NOTE
• Connect the ECU connector.
• Connect a digital meter [A] to the ECU connector [B] with

the needle adapter set.
ECU Power Supply Inspection

Connections:
Digital Meter (+) → R/W lead (ECU terminal 1)
Standard:
When battery is not connected: DC 0 V
When battery is connected: Battery Voltage
If the reading is out of the specification, check the follow-
ing.
Power Supply Wiring (see ECU Power Supply Circuit)
If the wiring is good, replace the ECU (see ECU Re-
moval/Installation).
ECU
ECU Power Supply Circuit
1. ECU
2. Capacitor
3. Frame Ground 1
Fuel Line
Fuel Pressure Inspection
NOTE
• Remove:
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump and the delivery pipe of the throttle
body assy.
WARNING
pipe because of residual pressure. Cover the hose
connection with a piece of clean cloth to prevent
fuel spillage.
• Install the fuel pressure gauge adapter [A] and fuel hoses
(Special Tool: 57001-1607) [B] between the fuel pump
and throttle body assy.
• Secure the fuel hoses with the clamps.
• Connect the pressure gauge [C] to the fuel pressure
gauge adapter.
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Fuel Pressure Gauge Adapter: 57001-1593
Fuel Hose: 57001-1607
WARNING
Fuel is extremely flammable and can be explosive
under certain conditions resulting in serious injury
or death. Do not try to start the engine with the fuel
hoses disconnected.
• Connect the fuel pump lead connector.

NOTE
○Inspect the fuel leakage from the connected portion of
the special tools.
NOTICE
Do not drive the fuel pump without the fuel in the
fuel tank. If the fuel pump is driven without the fuel,
it may be damaged.
Fuel Line
• Start the engine, and let it idle.

• Measure the fuel pressure with the engine idling.
Fuel Pressure
Standard: 294 kPa (3.0 kgf/cm², 43 psi) with engine
idling
NOTE
○The gauge needle will fluctuate. Read the pressure at
the average of the maximum and minimum indications.
• Stop the engine.

If the fuel pressure is much higher than specified, replace
the fuel pump because the fuel pressure regulator in the
fuel pump have been clogged or stuck.
If the fuel pressure is much lower than specified, check
the following.
Fuel Line Leakage (see Downstream/Upstream Injector
Fuel Line Inspection)
Amount of Fuel Flow (see Fuel Flow Rate Inspection)
• After above checks, measure the fuel pressure again.
• Remove the fuel pressure gauge, hoses and adapter.
• Start the engine and check for fuel leakage.
Fuel Flow Rate Inspection
WARNING
light.
NOTE
• Wait until the engine cools down.
• measuringa fuel
Prepare hose (Special Tool:
cylinder.
57001-1607) and a
Special Tool - Fuel Hose: 57001-1607

• Remove
moval).
the fuel tank bolt and band (see Fuel Tank Re-
Fuel Line
• Open
tank.
the fuel tank cap [A] to lower the pressure in the
• Disconnect the fuel hose from the fuel pump (see Fuel
Tank Removal).
○Be sure to place a piece of cloth around the fuel outlet
pipe of the fuel pump.
WARNING
fuel spillage.
• Connect the prepared fuel hose [A] to the fuel outlet pipe.
• Secure the fuel hose with a clamp.
• Insert the fuel hose into the measuring cylinder [B].
WARNING
Wipe off spilled out fuel immediately.
Be sure to hold the measuring cylinder vertical.
• Close the fuel tank cap.

○Then the fuel pump operates and fuel is discharged.
NOTICE
Do not operate the fuel pump without fuel in the fuel
tank. If the fuel pump is driven without fuel, it may
be damaged.
•○Measure the discharge for 5 seconds.

Repeat this operation several times.
Amount of Fuel Flow
Standard: 40 mL (1.4 US oz.) or more for 5 seconds
If the fuel flow is much less than the specified, replace the
fuel pump (see Fuel Pump Removal/Installation).
• Install the fuel tank (see Fuel Tank Installation).
• Start the engine and check for fuel leakage.
Throttle Grip and Cable
If the throttle grip has excessive free play due to cable
stretch or misadjustment, there will be a delay in throttle re-
sponse. Also, the throttle valve may not open fully at full
throttle. On the other hand, if the throttle grip has no play,
the throttle will be hard to control, and the idle speed will
be erratic. Check the throttle grip play periodically in accor-
dance with the Periodic Maintenance Chart, and adjust the
play if necessary.
The throttle cable routing is shown in Cable, Wire, and
Hose Routing section in the Appendix chapter.
Throttle Grip (Throttle Cable) Free Play Inspection
• Refer to the Throttle Grip Free Play Inspection in the Pe-
riodic Maintenance chapter.
Throttle Grip (Throttle Cable) Free Play
Adjustment
• Refer to the Throttle Grip Free Play Adjustment in the
Periodic Maintenance chapter.
Throttle Cable Replacement
• Slide
[B].
out the dust cover [A] and cable housing dust cover
• Remove the screws [C].

• Separate the throttle cable housing [D].
• Free the tips [A] from the grip [B].
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal)
Throttle Pulley Cover Bolts [A]
Throttle Pulley Cover [B]
Throttle Grip and Cable
• Loosen the locknut [A] and bolts [B].

• Free the the
Remove cables [C] from the throttle body assy.
• Pull out the
tips [D] from the pulley.
• cables from the frame.
• Lubricate the throttle cables (see Lubrication in the Peri-

odic Maintenance chapter).
• Apply grease to the throttle cable tips.
• Install the
Install throttle cable tips [A].
•○The accelerator
the bolts [B].
cable has washer, the bent side faces
inside.
• While holding the decelerator cable bolt, tighten the throt-
tle cable locknut [C] securely.
Torque - Throttle Cable Bolts: 3.0 N·m (0.31 kgf·m, 27 in·lb)
•○Install the throttle pulley cover.

Fit the projection [A] to the groove [B].
• Tighten:
Torque - Throttle Pulley Cover Bolts: 3.4 N·m (0.35 kgf·m,
30 in·lb)
Torque - Throttle Case Mounting Screws: 3.8 N·m (0.39
kgf·m, 34 in·lb)
• Install the throttle cables in accordance with the Cable,

• After the installation, adjust each cable properly (see
Throttle Grip Free Play Adjustment in the Periodic Main-
tenance chapter).
WARNING
Throttle Cable Lubrication

• Whenever the throttle cable is removed or in accordance
with the Periodic Maintenance Chart, lubricate the these
cables (see Lubrication in the Periodic Maintenance
chapter).
○Apply a thin coating of grease to the cable upper end.
○Use a commercially available pressure cable lubricator to
lubricate these cables.
Throttle Cable Inspection
• Refer to the Cable Inspection in the Periodic Maintenance
chapter.
Throttle Body Assy
Idle Speed Inspection
• Refer to the Idle Speed Inspection in the Periodic Main-
tenance chapter.
Throttle Bore Cleaning
• Refer to the Throttle Body Cleaning in the Periodic Main-
tenance chapter.
Throttle Body Assy Removal
WARNING
light.
NOTICE
Never drop the throttle body assy, especially on a
hard surface. Such a shock to the throttle body
assy can damage it.
• Remove:
Air Cleaner Housing with Rear Frame (see Rear Frame
• Disconnect:
Intake Air Pressure Sensor Connector [A]
Downstream Injector Connector [B]
Throttle Sensor Connector [C]
• Loosen the clamp screw [A].

• Removethrottle
Pull the body assy backward.
• Replacement). cable lower ends (see Throttle Cable
the throttle
Throttle Body Assy Installation

• Install the throttle body assy so that fit the projection [A]
on throttle body assy and groove [B] of the throttle body
holder.
NOTE
○For easily starting the engine, connect the 12 V battery
to the main harness (see Self-diagnosis Procedures).
○When the battery is connected, the fuel pump is driven
and the pressure of the fuel line increases.
Throttle Body Assy
Throttle Body Assy Disassembly
• Remove:
Throttle Body Assy (see Throttle Body Assy Removal)
Intake Air Pressure Sensor [A] (see Intake Air Pressure
Sensor Removal)
Downstream Injector [B] (see Downstream Injector Re-
moval)
Throttle Sensor [C] (see Throttle Sensor Replacement)
Idle Adjusting Screw Assy [D]
• Remove:
Screw [A]
Delivery Pipe [B]
• Remove:
Screws [A]
Plate [B]
Throttle Body Assy Assembly

• Replace the O-ring [A] of delivery pipe [B] with a new one.
• Install the delivery
Apply engine oil to the new O-ring.
• screw securely. pipe in the joint [C], and tighten the
• Install the plate so that fit the hollow [A] on the plate and
projection [B] on the throttle body assy.
• Tighten the screws securely.
Air Cleaner
Air Cleaner Housing Removal
• Remove the rear frame (see Rear Frame Removal in the
Frame chapter).
• Remove the air cleaner housing bolts [A].
• Take the air cleaner housing off the rear frame.
Air Cleaner Housing Installation

• Assemble
section).
the air cleaner housing (see Exploded View
• Install the air cleaner element (see Air Cleaner Element

Installation in the Periodic Maintenance chapter).
•○Install the air cleaner housing to the rear frame.

Insert the rear frame [A] to the holes [B] of the guard.
• Tighten the bolts [C] securely.
• Frame chapter).
Install the rear frame (see Rear Frame Installation in the
Element Removal/Installation
• Refer to the Air Cleaner Element Cleaning and Inspection
in the Periodic Maintenance chapter.
Element Cleaning and Inspection
• Refer to the Air Cleaner Element Cleaning and Inspection
Fuel Tank
Fuel Tank Removal
WARNING
light.
• Remove:
Radiator Shrouds (see Radiator Shroud Removal in the
Frame chapter)
Fuel Tank Bolt [A]
Band [B]
• Draw the fuel out from the fuel tank with a commercially
available pump [A].
○Use a soft plastic hose [B] as a pump intake hose in order
to insert the hose smoothly.
○Put the hose through the fill opening [C] into the tank and
draw the fuel out.
WARNING
Spilled fuel is flammable and can be explosive un-
der certain conditions. The fuel can not be removed
completely from the fuel tank. Be careful for re-
mained fuel spillage.
• Lift up the fuel tank, and disconnect the fuel pump lead
connector [A].
• Be sure to place a piece of cloth around the fuel hose joint.

• Wipe off the dirt of the surface [A] around the connection
using a cloth or a soft brush.
Fuel Tank
the joint lock [C].

NOTICE
around the housing.
• Disconnect the fuel hose joint [A] from the fuel outlet pipe.
WARNING
fuel spillage.
• Close the fuel tank cap.

•○Do not apply
Remove the fuel tank, and place a it on a flat surface.
the load to the fuel outlet pipe of the fuel
pump.
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions, creating the poten-
tial for serious burns. Store the fuel tank in an area
which is well-ventilated and free from any source of
flame or sparks. Do not smoke in this area. Place
the fuel tank on a flat surface and plug the fuel pipes
to prevent fuel leakage.
Fuel Tank
• Clean the pipe [A].

• to keepthethem
Cover pipe and hose joint [B] with the vinyl bags [C]
clean.
Fuel Tank Installation

• Note the above WARNING (see Fuel Tank Removal).
• Run the hoses correctly (see Cable, Wire, and Hose Rout-
ing section in the Appendix chapter).
• Check that the dampers [A] are in place on the frame.
If the dampers are damaged or deteriorated, replace it.
○Using a high flash-point solvent, clean any oil or dirt that
may be on the adhesive cement coating area. Dry them
with a clean cloth.
If necessary, apply adhesive cement to the underside of
the dampers, and stick them.
• Remove the vinyl bags on the pipe and hose joint.

• foreign materials
Check that there are no flaws, burrs, and adhesion of
on fuel outlet pipe [A].
• Check the joint lock for deformation and wear.
• new one. lock is deformed, replace the fuel hose with a
If the joint
• Apply engine oil to the fuel outlet pipe [A] lightly.
• Insert [A] the fuel hose joint [B] straight onto the fuel outlet
pipe until the hose joint clicks.
• Push [C] the joint lock [D].
Fuel Tank
• Push and pull [A] the fuel hose joint back and forth more
than two times, and make sure it is locked and does not
come off.
WARNING
Leaking fuel can cause a fire or explosion resulting
in serious burns. Make sure the hose joint is in-
stalled correctly on the delivery pipe by sliding the
joint.
If it comes off, reinstall the hose joint.
• Connect the fuel pump lead connector.
• Hook the band to the fuel tank.

• After installing
Tighten the fuel tank bolt.
• cables [A] (outer)
the fuel tank, make sure that both throttle
move slightly by pulling them back and
forth in the upper space of the right side of the fuel tank
[B]. Check that both throttle cables run under the frame
(right side) [C].
NOTE
○Check the fuel hose position. If the fuel hose interferes
with the cylinder head cover, move the fuel hose up-
ward.
•○Install the removed parts (see appropriate chapters).

Insert the fuel tank breather hose into the steering stem
hole.
NOTE
○For easily starting the engine, connect the 12 V battery
to the main harness (see Self-diagnosis Procedures).
○When the battery is connected, the fuel pump is driven
and the pressure of the fuel line increases.
Fuel Tank Cleaning

• Refer to the Fuel Tank Cleaning in the Periodic Mainte-
nance chapter.
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................ 4-2
Specifications ......................................................................................................................... 4-4
Special Tool ............................................................................................................................ 4-5
Coolant ................................................................................................................................... 4-6
Coolant Level Inspection................................................................................................... 4-6
Coolant Deterioration Inspection....................................................................................... 4-6 4
Coolant Draining ............................................................................................................... 4-6
Coolant Filling ................................................................................................................... 4-7
Air Bleeding....................................................................................................................... 4-7
Cooling System Pressure Testing ..................................................................................... 4-8
Cooling System Flushing .................................................................................................. 4-8
Water Pump............................................................................................................................ 4-9
Water Pump Cover Removal ............................................................................................ 4-9
Water Pump Cover Installation ........................................................................................ 4-9
Impeller Removal .............................................................................................................. 4-10
Impeller Installation ........................................................................................................... 4-10
Water Pump Inspection..................................................................................................... 4-10
Water Pump Gear Removal .............................................................................................. 4-10
Water Pump Gear Installation ........................................................................................... 4-11
Oil Seal and Bearing Removal.......................................................................................... 4-11
Oil Seal and Bearing Installation....................................................................................... 4-11
Radiator .................................................................................................................................. 4-12
Radiator Removal ............................................................................................................. 4-12
Radiator Installation .......................................................................................................... 4-13
Radiator Inspection ........................................................................................................... 4-13
Radiator Cap Inspection ................................................................................................... 4-14
Filler Neck Inspection........................................................................................................ 4-14
Water Hoses and Overflow Hose Inspection .................................................................... 4-14
Water Hoses and Overflow Hose Installation ................................................................... 4-14
4-2 COOLING SYSTEM
Exploded View
COOLING SYSTEM 4-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Water Hose Clamp Screws 3.0 0.31 27 in·lb
2 Water Pipe Bolt 9.8 1.0 87 in·lb
3 Water Pump Cover Bolts (L = 55 mm) 9.8 1.0 87 in·lb L
4 Water Pump Impeller Bolt 7.0 0.71 62 in·lb
5 Water Pump Cover Bolts (L = 30, 65 mm) 9.8 1.0 87 in·lb
6 Coolant Drain Bolt 7.0 0.71 62 in·lb
G: Apply grease.
WL: Apply soap and water solution.
4-4 COOLING SYSTEM
Specifications
Item Standard
Recommended Coolant
Type Permanent type antifreeze (soft water and ethylene glycol
plus corrosion and rust inhibitor chemicals for aluminum
engines and radiators)
Color Green
Mixed Ratio Soft water 50%, coolant 50%
Freezing Point –35°C (–31°F)
Total Amount 1.2 L (1.3 US qt)
Radiator
Radiator Cap Relief Pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
COOLING SYSTEM 4-5
Special Tool
Bearing Driver Set:
57001-1129
4-6 COOLING SYSTEM
Coolant
Coolant Level Inspection
• Refer to the Coolant Level Inspection in the Periodic Main-
tenance chapter.
Coolant Deterioration Inspection
• Refer to the Coolant Deterioration Inspection in the Peri-
odic Maintenance chapter.
Coolant Draining
WARNING
Coolant can be extremely hot and cause severe
burns, is toxic and very slippery. Do not remove
the radiator cap or attempt to change the coolant
when the engine is hot; allow it cool completely.
Immediately wipe any spilled coolant from tires,
frame, engine or other painted parts. Do not ingest
coolant.
NOTICE
The coolant should be changed periodically to en-
sure long engine life.
• Remove:
Right Radiator Shroud (see Radiator Shroud Removal in
the Frame chapter)
Radiator Cap [A]
NOTE
○Remove the radiator cap in two steps. First turn the
cap counterclockwise to the first stop and wait there for
a few seconds. Then push down and turn it further in
the same direction and remove the cap.
• Place a container under the coolant drain bolt [A].

• Inspect thetheolddrain
Remove bolt to drain the coolant.
• tion in the Periodic Maintenance
coolant (see Coolant Deterioration Inspec-
chapter).
COOLING SYSTEM 4-7
Coolant
Coolant Filling
NOTICE
Use coolant containing corrosion inhibitors made
specifically for aluminum engines and radiators in
accordance with the instruction of the manufac-
ture’s. Soft or distilled water must be used with the
antifreeze (see below for antifreeze) in the cooling
system. If hard water is used in the system, it
causes scale accumulation in the water passages,
and considerably reduces the efficiency of the
cooling system.
Recommended Coolant
Type: Permanent type antifreeze (soft water
and ethylene glycol plus corrosion
and rust inhibitor chemicals for
aluminum engines and radiators)
Color: Green
Mixed Ratio: Soft water 50%, coolant 50%
Freezing Point: −35°C (−31°F)
Total Amount: 1.2 L (1.3 US qt)
• Replace the drain bolt gasket with a new one.

• Tighten:
Torque - Coolant Drain Bolt: 7.0 N·m (0.71 kgf·m, 62 in·lb)
• Fill the radiator up to the bottom of the radiator filler neck

[A] with coolant [B], and install the cap.
○Lean the motorcycle slightly so that the filler neck is lo-
cated uppermost in order to exhaust the air accumulated
in the radiator.
NOTE
○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
○The radiator cap must be installed in two steps. First
turn the cap clockwise to the first stop. Then push down
on it and turn it the rest of the way.
• Check the cooling system for leaks.

Air Bleeding
• Start the engine, warm up the engine thoroughly, and then
stop the engine.
• Wait until the engine cools down.
• Check thethecoolant
Remove radiator cap.
• the Periodic Maintenance
level (see Coolant Level Inspection in
chapter).
If the coolant level is low, add coolant up to the bottom of
the filler neck.
• Install the radiator cap.
• Check the cooling system for leaks.
4-8 COOLING SYSTEM
Coolant
Cooling System Pressure Testing
NOTICE
During pressure testing, do not exceed the pres-
sure for which the system is designed to work. The
maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
• Remove the radiator cap, and install a cooling system

pressure tester [A] and adapter [B] on the radiator filler
neck [C].
NOTE
○Wet the adapter cap sealing surfaces with water or
coolant to prevent pressure leaks.
• Build up pressure in the system carefully until the pres-

sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
• Watch the gauge for at least 6 seconds.
If the pressure holds steady, the cooling system is all right.
If the pressure drops and no external source is found,
check for internal leaks. Check the cylinder head gasket
for leaks.
• Remove the pressure tester, replenish the coolant, and
install the radiator cap.
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. 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.
• Drain the cooling system (see Coolant Draining).
• Fill the cooling system with fresh water mixed with a flush-
ing compound.
NOTICE
Avoid the use of a flushing compound which is
harmful to the aluminum engine and radiators.
Carefully follow the instructions supplied by the
manufacture of the cleaning product.
• Warm up the engine, and run it at normal operating tem-

perature for about 10 minutes.
• Stop the engine, and drain the cooling system after the
coolant cools down.
• Fill the system with fresh water.
• Warm up the engine and drain the system after the
coolant cools down.
• Repeat the previous two steps once more.
• the air from thewith
Fill the system a permanent type coolant, and bleed
system (see Air Bleeding).
COOLING SYSTEM 4-9
Water Pump
Water Pump Cover Removal
• Remove the oil filter (see Oil Filter Change in the Periodic
Maintenance chapter).
○Drain the engine oil from the water pump cover.
• Drain the coolant (see Coolant Draining).
• pipe [B]. the water pipe bolt [A], and disconnect the water
Remove
• Remove the water pump cover bolts [C].
• Using the pry points [A], remove the pump cover [B].
Water Pump Cover Installation

• Install:
Dowel Pins [A]
• Apply grease
Replace the pump cover gasket [B] with a new one.
• to the pump cover gasket.
• Install the water pump cover.

• Replace the washers [A] with new ones.
• in.) bolts [B].
Apply a non-permanent locking agent to the 55 mm (2.2
• Tighten:
Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Coolant Drain Bolt: 7.0 N·m (0.71 kgf·m, 62 in·lb)
• Replace the water pipe O-ring [A] with a new one.

• Apply soap and water solution to the new O-ring.
• ter pump cover.
Insert the water pipe [B] straightly into the hole of the wa-
• Tighten:
Torque - Water Pipe Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the oil filter (see Oil Filter Change in the Periodic
• Fill the coolant (see Coolant Filling).
• Checkthe
Bleed air from the cooling system (see Air Bleeding).
• Engine Oil Change
the engine oil level and add the engine oil (see
in the Periodic Maintenance chapter).
4-10 COOLING SYSTEM
Water Pump
Impeller Removal
• Remove:
Water Pump Cover (see Water Pump Cover Removal)
• and washer.
Remove the impeller bolt [A] and take out the impeller [B]
Impeller Installation
• Install the washer [A] and impeller [B].
• Tighten:
Torque - Water Pump Impeller Bolt: 7.0 N·m (0.71 kgf·m, 62
in·lb)
• Install the water pump cover (see Water Pump Cover In-
stallation).
Water Pump Inspection

• Visually check the impeller [A].
If the surface is corroded, or if the blades [B] are dam-
aged, replace the impeller.
• Check the drainage outlet passage [A] at the bottom of

the right engine cover for coolant leaks.
If the oil seal is damaged, the coolant leaks through the
seal and drains through the passage. Replace the oil
seals.
Water Pump Gear Removal

• Remove:
Water Pump Cover (see Water Pump Cover Removal)
Impeller (see Impeller Removal)
Right Engine Cover (see Right Engine Cover Removal
in the Clutch chapter)
• Pull out the water pump gear [A] together with shaft.
COOLING SYSTEM 4-11
Water Pump
Water Pump Gear Installation
• Press in the water pump gear shaft [A] to the gear [B] until
it is bottomed.
• Apply grease to the water pump gear shaft.
• Install the gear shaft from bearing side [C].
NOTICE
Be sure to apply grease to the water pump shaft
when installing. If it is installed dry, the seals may
wear excessively.
• Install
freely.
the impeller and check to see that the impeller turn
Oil Seal and Bearing Removal

• Remove:
Water Pump Gear (see Water Pump Gear Removal)
• Insert a bar [A] into the water pump shaft hole from the
outside.
• Tapping evenly around the inner race to remove the ball
bearing [B].
• Remove the oil seal [C] from the right engine cover in the
same way as ball bearing removal.
• Insert
inside.
a bar [A] into the water pump shaft hole from the
• Remove
seal lips.
the oil seal [B] by tapping [C] evenly around the
Oil Seal and Bearing Installation

NOTICE
If the oil seal or ball bearing is removed, replace all
of them with new ones at the same time.
• Replace the oil seals with new ones.

• Press in the oilof grease
Apply plenty to the oil seal lips.
•○Press in the oil seal
seals direction as shown.
using a bearing driver set so that the
seal surface is flush with the surface of the right engine
cover.
Flat Side [A]
Water Pump Oil Seals [B]
Special Tool - Bearing Driver Set: 57001-1129
• Press the ball bearing [C] into the hole until the face of the
bearing is even with the end of the hole.
4-12 COOLING SYSTEM
Radiator
Radiator Removal
• Drain the coolant (see Coolant Draining).
• Remove:
Radiator Shrouds (see Radiator Shroud Removal in the
Frame chapter)
• Remove the capacitor [A] (see Capacitor Removal in the

• Loosen:
Water Hose Clamp Screws [B]
• Slide the clamp [C].
• Remove: the water hoses [D] from the radiator.
Disconnect
• Radiator Screen Bolt [E]
Left Radiator Screen [F]
○Clear the projection [G] from the hole.
• Remove:
Radiator Mounting Bolts [A], Clamps and Washers
Left Radiator [B]
• Loosen:
Water Hose Clamp Screws [A]
• Disconnect
Slide the clamp [B].
• Remove: the water hoses [C] from the radiator.
• Radiator Screen Bolt [D]
Right Radiator Screen [E]
○Clear the projection [F] from the hole.
• Remove:
Radiator Mounting Bolts [A] and Washers
Overflow Hose [B]
Right Radiator [C]
COOLING SYSTEM 4-13
Radiator
Radiator Installation
• Install:
Radiators
Washers
Clutch Cable Clamps [A] (Left Side)
• Tighten the radiator mounting bolts securely.
• Run the overflow hose and water hoses correctly (see
Cable, Wire, and Hose Routing section in the Appendix
chapter).
• Tighten:
27 in·lb)
•○Install the radiator screens on both sides.

Fit the projections [A] and holes [B].
• Tighten the radiator screen bolts securely.
• Install the removed
Fill the coolant (see Coolant Filling).
• parts (see appropriate chapters).
Radiator Inspection
• Check the radiator core.
If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten them with the standard tip screwdriver.
NOTICE
Do not tear the radiator tubes while straightening
the fins.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably de-
formed fins, replace the radiator with a new one.
NOTICE
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.64
ft) [B] from the radiator core. Hold the steam gun
perpendicular to the core surface. Run the steam
gun following the core fin direction [C].
4-14 COOLING SYSTEM
Radiator
Radiator Cap Inspection
• Check the top and bottom valve seals [A] of the radiator
cap, and the condition of the valve spring [B].
If any one of them shows visible damage, replace the cap.
• Wet the top and bottom valve seals with water or coolant
to prevent pressure leaks.
• Install the cap [A] on a cooling system pressure tester [B].
• tester to build
Watching the pressure gauge, slowly pump the pressure
up the pressure. The gauge hand must
remain within the relief pressure range in the table below
at least 6 seconds. Continue to pump the tester until the
relief valve opens, indicated by the gauge hand flicking
downward. The relief valve must open within the specified
range.
Radiator Cap Relief Pressure
Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18
psi)
If the cap cannot hold the pressure, or if the relief pressure
is too high or too low, replace the cap with a new one.
Filler Neck Inspection
• Check the radiator filler neck for signs of damage.
• Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
Water Hoses and Overflow Hose Inspection

• Refer to the Water Hoses and Connections Inspection in
the Periodic Maintenance chapter.
Water Hoses and Overflow Hose Installation
• Install the water hoses or overflow hose being careful to
follow the performed bends (see Cable, Wire, and Hose
Routing section in the Appendix chapter). Avoid sharp
bending, kinking, flattening, or twisting.
• Tighten the hose clamps securely.
27 in·lb)
ENGINE TOP END 5-1
Engine Top End

Table of Contents
Exploded View................................... 5-2 Valve Guide Installation ............... 5-27
Specifications .................................... 5-6 Valve/Valve Guide Clearance
Special Tools and Sealant ................. 5-9 Measurement (Wobble Method) 5-28
Cylinder Head Cover ......................... 5-12 Valve Seat Inspection .................. 5-29
Cylinder Head Cover Removal .... 5-12 Valve Seat Repair ........................ 5-29
Cylinder Head Cover Installation . 5-12 Cylinder and Piston ........................... 5-34
Camshaft Chain Tensioner ................ 5-14 Cylinder Removal......................... 5-34
Camshaft Chain Tensioner
Removal .................................... 5-14
Piston Removal............................
Cylinder and Piston Installation....
5-34
5-34
5
Camshaft Chain Tensioner Cylinder Wear Inspection............. 5-36
Installation ................................. 5-14 Piston Wear Inspection ................ 5-36
Camshafts ......................................... 5-15 Piston/Cylinder Clearance
Camshaft Removal ...................... 5-15 Inspection.................................. 5-36
Camshaft Installation ................... 5-16 Piston Ring/Ring Groove
Camshaft Chain Removal ............ 5-19 Clearance Inspection ................ 5-36
Camshaft Chain Installation ......... 5-19 Piston Ring Groove Width
Camshaft and Camshaft Cap Inspection.................................. 5-37
Wear Inspection ........................ 5-19 Piston Ring Thickness Inspection 5-37
Camshaft Runout Inspection........ 5-20 Piston Ring End Gap
Cam Wear Inspection .................. 5-20 Measurement ............................ 5-37
Cylinder Head.................................... 5-21 Piston, Piston Pin, Connecting
Cylinder Compression Rod Wear Inspection................. 5-38
Measurement ............................ 5-21 Throttle Body Assy Holder................. 5-39
Cylinder Head Removal ............... 5-22 Throttle Body Assy Holder
Cylinder Head Installation ............ 5-23 Removal .................................... 5-39
Cylinder Head Cleaning ............... 5-23 Throttle Body Assy Holder
Cylinder Head Warp Inspection ... 5-24 Installation ................................. 5-39
Valves ................................................ 5-25 Muffler................................................ 5-40
Valve Clearance Inspection ......... 5-25 Muffler Body Removal.................. 5-40
Valve Clearance Adjustment........ 5-25 Exhaust Pipe Removal................. 5-40
Valve Removal ............................. 5-25 Muffler Installation........................ 5-40
Valve Installation .......................... 5-26 Silencer Wool Replacement......... 5-40
Valve Guide Removal .................. 5-27
5-2 ENGINE TOP END
Exploded View
ENGINE TOP END 5-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
2 Camshaft Cap Bolts 9.8 1.0 87 in·lb MO, S
3 Plug 20 2.0 15 L
4 Cylinder Head Bolts (M10) 44 4.5 32 MO, R, S
5 Auto-Decompressor Bolt 12 1.2 106 in·lb
6 Cylinder Head Bolts (M6) 12 1.2 106 in·lb S
7 Cylinder Bolt 12 1.2 106 in·lb S
8 Throttle Body Assy Holder Clamp Screw 2.0 0.20 18 in·lb
9 Throttle Body Assy Clamp Screw 2.0 0.20 18 in·lb
10 Lower Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb
11 Rear Camshaft Chain Guide Bolt 15 1.5 11
12 Camshaft Chain Tensioner Cap Bolt 20 2.0 15
13 Camshaft Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb
G: Apply grease.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
5-4 ENGINE TOP END
Exploded View
ENGINE TOP END 5-5
Exploded View
G: Apply grease.
SS: Apply silicone sealant.
5-6 ENGINE TOP END
Specifications

Camshafts
Cam Height:
Exhaust 33.943 ∼ 34.057 mm 33.84 mm
(1.3363 ∼ 1.3408 in.) (1.332 in.)
Intake 35.243 ∼ 35.357 mm 35.14 mm
(1.3875 ∼ 1.3920 in.) (1.383 in.)
Camshaft Journal/Camshaft Cap 0.020 ∼ 0.062 mm 0.15 mm
Clearance (0.0008 ∼ 0.0024 in.) (0.0059 in.)
Camshaft Journal Diameter 21.959 ∼ 21.980 mm 21.93 mm
(0.8645 ∼ 0.8654 in.) (0.8634 in.)
Camshaft Bearing Inside Diameter 22.000 ∼ 22.021 mm 22.08 mm
(0.8661 ∼ 0.8670 in.) (0.8693 in.)
Camshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm
(0.004 in.)
Cylinder Head
Cylinder Compression (Usable Range) – – –
427 ∼ 708 kPa (4.4 ∼ 7.2 kgf/cm²,
62 ∼ 103 psi) at 5 times
Cylinder Head Warp ––– 0.05 mm (0.002 in.)
Valves
Valve Clearance:
Exhaust 0.17 ∼ 0.22 mm
– – –
(0.0067 ∼ 0.0087 in.)
Intake 0.10 ∼ 0.15 mm
– – –
(0.0039 ∼ 0.0059 in.)
Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm
(0.002 in.)
Valve Stem Diameter:
Exhaust 4.455 ∼ 4.470 mm 4.44 mm (0.175 in.)
(0.1754 ∼ 0.1760 in.)
Intake 4.475 ∼ 4.490 mm 4.46 mm (0.176 in.)
(0.1762 ∼ 0.1768 in.)
Valve Guide Inside Diameter:
Exhaust 4.500 ∼ 4.512 mm 4.58 mm (0.180 in.)
(0.1772 ∼ 0.1776 in.)
Intake 4.500 ∼ 4.512 mm 4.58 mm (0.180 in.)
(0.1772 ∼ 0.1776 in.)
Valve/Valve Guide Clearance (Wobble
Method):
Exhaust 0.07 ∼ 0.13 mm 0.30 mm (0.012 in.)
(0.0028 ∼ 0.0051 in.)
Intake 0.02 ∼ 0.09 mm 0.22 mm (0.009 in.)
(0.0008 ∼ 0.0035 in.)
Valve Seat Cutting Angle 32°, 45°, 60° – – –
ENGINE TOP END 5-7
Specifications

Valve Seating Surface:
Outside Diameter:
Exhaust 24.6 ∼ 24.8 mm – – –
(0.969 ∼ 0.976 in.)
Intake:
KX250ZD ∼ ZE 30.6 ∼ 30.8 mm – – –
(1.205 ∼ 1.213 in.)
KX250ZF 30.5 ∼ 30.7 mm – – –
(1.201 ∼ 1.209 in.)
Width:
Exhaust 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – –
Intake 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – –
Valve Spring Free Length:
Exhaust 37.88 mm (1.491 in.) 36.5 mm (1.44 in.)
Intake 36.20 mm (1.425 in.) 34.7 mm (1.37 in.)
Cylinder, Piston
Cylinder Inside Diameter:
KX250ZD ∼ ZE 77.000 ∼ 77.012 mm 77.10 mm
(3.0315 ∼ 3.0320 in.) (3.035 in.)
KX250ZF 76.998 ∼ 77.014 mm 77.10 mm
(3.0314 ∼ 3.0320 in.) (3.035 in.)
Piston Diameter 76.948 ∼ 76.963 mm 76.80 mm
(3.0294 ∼ 3.0300 in.) (3.024 in.)
Piston/Cylinder Clearance 0.041 ∼ 0.068 mm
– – –
(0.0016 ∼ 0.0027 in.)
Piston Ring/Ring Groove Clearance:
Top 0.04 ∼ 0.08 mm 0.18 mm
(0.002 ∼ 0.003 in.) (0.0071 in.)
Piston Ring Groove Width:
Top 0.83 ∼ 0.85 mm 0.93 mm
(0.0327 ∼ 0.0335 in.) (0.037 in.)
Piston Ring Thickness:
Top 0.77 ∼ 0.79 mm 0.70 mm
(0.030 ∼ 0.031 in.) (0.028 in.)
Piston Ring End Gap:
Top 0.15 ∼ 0.25 mm 0.6 mm
(0.0059 ∼ 0.0098 in.) (0.02 in.)
Oil 0.20 ∼ 0.70 mm 1.0 mm
(0.0079 ∼ 0.0276 in.) (0.04 in.)
Piston Pin Diameter 15.991 ∼ 16.000 mm 15.96 mm
(0.62957 ∼ 0.62992 in.) (0.6283 in.)
Piston Pin Hole Diameter 16.004 ∼ 16.010 mm 16.08 mm
(0.63008 ∼ 0.63031 in.) (0.6331 in.)
Connecting Rod Small End Inside 16.010 ∼ 16.018 mm 16.05 mm
Diameter (0.63031 ∼ 0.63063 in.) (0.6319 in.)
5-8 ENGINE TOP END
Specifications
Valve Stem Diameter Valve Stem Bend
Valve Stem Diameter [A] Dial Gauge [A]

45° [B]
ENGINE TOP END 5-9
Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 32:
57001-221 57001-1115
Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 28:

57001-241 57001-1119
Piston Ring Compressor Grip: Valve Seat Cutter Holder Bar:

57001-1095 57001-1128
Piston Ring Compressor Belt, 67 ∼ 79: Valve Seat Cutter, 32° - 33:
57001-1097 57001-1199
Valve Seat Cutter, 45° - 27.5: Valve Spring Compressor Adapter, 22:
57001-1114 57001-1202
5-10 ENGINE TOP END
Compression Gauge Adapter, M10 × 1.0: Valve Seat Cutter, 60° - 33:
57001-1317 57001-1334
Valve Seat Cutter, 60° - 25: Filler Cap Driver:

57001-1328 57001-1454
Valve Seat Cutter Holder, 4.5: Valve Guide Driver:

57001-1330 57001-1564
Valve Guide Arbor, 4.5: Piston Pin Puller:

57001-1331 57001-1568
Valve Guide Reamer, 4.5: Valve Spring Compressor Adapter, 24:

57001-1333 57001-1586
ENGINE TOP END 5-11
Valve Guide Driver Attachment, F: Liquid Gasket, TB1216B:
57001-1722 92104-1064
5-12 ENGINE TOP END
Cylinder Head Cover
Cylinder Head Cover Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Spark Plug Cap [A]
Cylinder Head Cover Bolts [B] and Washers
Cylinder Head Cover [C]
• Remove the cylinder head cover gasket [A].
Cylinder Head Cover Installation

that may be on the liquid gasket coating area. Dry them
with a clean cloth.
• Apply liquid gasket [A] to the cylinder head.
Sealant - Liquid Gasket, TB1216B: 92104-1064
NOTE
○Make the application finish within 20 minutes when the
liquid gasket (TB1216B) to the mating surface of the
cylinder head cover is applied.
• Replace the spark plug hole gasket [A] with a new one,
and install it.
• Make sure that the upper chain guide [A] is bottomed.

NOTICE
Unless the upper chain guide is bottomed, the
camshaft chain could push the cylinder head cover
upward, leading to an oil leak.
• Replace the cylinder head cover gasket with a new one.

• der head cover
Install the new cylinder head cover gasket [B] on the cylin-
[C].
• Install the cylinder head cover.
ENGINE TOP END 5-13
Cylinder Head Cover
• Install the cylinder head cover bolt washers with the metal
side [A] upwards.
• Tighten:
Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m,
87 in·lb)
5-14 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
NOTICE
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below:
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in “Camshaft Chain Ten-
sioner Installation”.
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing and damage the valves.
• Remove:
Cap Bolt [A]
Washer [B]
Spring
Rod
• Remove the mounting bolts [C] and take off the camshaft
chain tensioner body [D].
Camshaft Chain Tensioner Installation

• Replace the O-ring [A] with a new one.
• Release the stopper
Apply grease to the O-ring.
• the tensioner body [D][B]fully.
and push the push rod [C] into
• Install
ward.
the tensioner body so that the stopper faces up-
○Turn the stopper to right side of the motorcycle.
• Tighten:
Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 9.8
N·m (1.0 kgf·m, 87 in·lb)
• Install the spring [B] and rod [C].
• Tighten the cap bolt [D] together with the washer [E].
Torque - Camshaft Chain Tensioner Cap Bolt: 20 N·m (2.0
kgf·m, 15 ft·lb)
ENGINE TOP END 5-15
Camshafts
Camshaft Removal
• Remove:
moval)
Timing Inspection Cap [A]
Flywheel Nut Cap [B]
•○Bring the piston to the TDC of the compression stroke.

Place a wrench over the flywheel nut [A] and turn it coun-
• Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Camshaft Cap Bolts [1 ∼ 8] (sequence numbers, gradu-
ally and evenly)
Camshaft Cap [A]
• Remove:
Positioning Rings [A]
• Disengage the camshafts [B] from camshaft chain [C].
• Staff a clean cloth into the camshaft chain tunnel to keep

any parts from dropping into the crankcase.
NOTICE
Always strain the camshaft chain while turning the
crankshaft when the camshafts removed.
This avoids kinking the chain on the lower (crank-
shaft) sprocket. A kinked chain could damage both
the chain and the sprocket.
5-16 ENGINE TOP END
Camshafts
• Remove:
Bolt [A]
Auto-Decompressor [B]
Spring [C]
Camshaft Installation
• When installing the spring [A] on the auto-decompressor
[B], put the spring end [C] onto the outside coil.
• Install the
camshaft.
auto-decompressor [A] in the exhaust
• Tighten:
Torque - Auto-Decompressor Bolt [B]: 12 N·m (1.2 kgf·m,
106 in·lb)
○The intake camshaft has projection [A].
• Replace
it.
the O-ring [A] with a new one, and apply grease
• Fill the oil passage [B] of the cylinder head with engine oil.
• ing, allmolybdenum
Apply disulfide oil solution to the ball bear-
cam and journal surfaces of the camshafts.
If the new camshaft is installed, apply a thin coat of molyb-
denum disulfide grease to the cam and journal surfaces
of the camshaft.
ENGINE TOP END 5-17
Camshafts
•○Bring the piston to the TDC.

Place a wrench over the flywheel nut [A] and turn it coun-
•○Engage the camshaft chain with the camshaft sprockets.

Align the timing marks on the sprockets with the cylinder
head upper surface.
○Starting with the timing mark on the front of the exhaust
sprocket, count to the 1st pin. Feed the exhaust camshaft
thought the chain and align the 28th pin with the timing
mark on the intake camshaft sprocket.
NOTE
○Strain the exhaust-side of the chain while installing the
camshaft.
1st Pin [A] Punch Marks (Exhaust) [D]

2nd Pin [B] Punch Marks (Intake) [E]
28th Pin [C] Cylinder Head Upper Surface [F]
5-18 ENGINE TOP END
Camshafts
• Install the dowel pins [A] and positioning rings [B].
• Apply molybdenum disulfide oil solution to the threads

and seating surface of the camshaft cap bolts.
• Tighten all camshaft cap bolts evenly and lightly, and then
tighten them with specified torque.
○Follow the numbers [1 ∼ 8] of tightening sequence on the
camshaft cap.
○Bolt [5] is long.
Torque - Camshaft Cap Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Replace
it.
the O-ring [A] with a new one, and apply grease
• Install the camshaft chain tensioner (see Camshaft Chain

Tensioner Installation).
•○Check the camshaft chain timing.
Confirm the timing mark and punch mark align with the
cylinder head upper surface.
If the timing mark and punch mark do not align with the
cylinder head upper surface, reinstall the camshafts.
○Turn the crankshaft slowly.
If the crankshaft does not turn smoothly, the timing is dif-
ferent. Stop turning immediately.
NOTICE
The improper camshaft chain timing may damage
the valves.
• Install:
Cylinder Head Cover (see Cylinder Head Cover Instal-
lation)
• Replace the timing inspection cap and flywheel nut cap
O-rings with new ones, and apply grease them.
• Tighten:
Torque - Timing Inspection Cap: 3.5 N·m (0.36 kgf·m, 31
in·lb)
Flywheel Nut Cap: 3.5 N·m (0.36 kgf·m, 31 in·lb)
ENGINE TOP END 5-19
Camshafts
Camshaft Chain Removal
• Remove:
Camshafts (see Camshaft Removal)
Flywheel (see Flywheel Removal in the Electrical Sys-
tem chapter)
Lower Camshaft Chain Guide Bolt [A]
Lower Camshaft Chain Guide [B]
• Disengage the camshaft chain [C] from the crankshaft.
Camshaft Chain Installation

• Engage the camshaft chain to the crankshaft.
• Install the lower camshaft chain guide.
• Tighten:
Torque - Lower Camshaft Chain Guide Bolt: 9.8 N·m (1.0
kgf·m, 87 in·lb)
• Install:
Flywheel (see Flywheel Installation in the Electrical Sys-
tem chapter)
Camshafts (see Camshaft Installation)
Camshaft and Camshaft Cap Wear Inspection
• Measure each clearance between the camshaft journal
and camshaft cap using plastigage (press gauge) [A].
○Tighten the camshaft cap bolts after applying molybde-
num disulfide oil to the seat and thread of them.
Torque - Camshaft Cap Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
NOTE
○Do not turn the camshaft when the plastigage is be-
tween the journal and camshaft cap.
Camshaft Journal/Camshaft Cap Clearance

Standard: 0.020 ∼ 0.062 mm (0.0008 ∼ 0.0024 in.)
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard: 21.959 ∼ 21.980 mm (0.8645 ∼ 0.8654 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one, and measure
the clearance again.
If the clearance still remains out of the service limit, re-
place the cylinder head unit.
5-20 ENGINE TOP END
Camshafts
Camshaft Runout Inspection
• Remove the camshafts (see Camshaft Removal).
• Set the camshaft in a camshaft alignment jig or on V
blocks.
• Measure
place.
the runout with a dial gauge [A] at the specified
If the runout exceeds the service limit, replace the

camshaft.
Camshaft Runout
Cam Wear Inspection

• Remove the camshafts (see Camshaft Removal).
• Measure the height [A] of each cam with a micrometer.
Cam Height
Standard:
Exhaust 33.943 ∼ 34.057 mm (1.3363 ∼ 1.3408 in.)
Intake 35.243 ∼ 35.357 mm (1.3875 ∼ 1.3920 in.)
Service Limit:
Exhaust 33.84 mm (1.332 in.)
Intake 35.14 mm (1.383 in.)
If the cams are worn down past the service limit, replace
the camshaft.
ENGINE TOP END 5-21
Cylinder Head
Cylinder Compression Measurement
• Warm up the engine thoroughly.
• Fuel Tank (see Fuel Tank Removal in the Fuel System
Remove:
(DFI) chapter)
Spark Plug (see Spark Plug Cleaning and Inspection in
the Periodic Maintenance chapter)
• Attach the compression gauge [A] and compression

gauge adapter [B] firmly into the spark plug hole.
•○Measure the compression pressure.
With the throttle fully open, turn the engine over sharply
with the kickstarter several times until the compression
gauge stops rising; the compression is the highest read-
ing obtainable.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M10 × 1.0:
57001-1317
Cylinder Compression
Usable Range: 427 ∼ 708 kPa (4.4 ∼ 7.2 kgf/cm², 62 ∼
103 psi) at 5 times

If the compression pressure is not within the usable range,
check the following table.
Problem Diagnosis Remedy (Action)

The cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace
compression is cylinder head (combustion chamber) is damaged parts if necessary.
higher than the suspected due to damaged valve stem
usable range. or piston oil rings.
Incorrect cylinder head gasket Replace the gasket with a standard one.
thickness
Damaged auto-decompressor spring or Replace the spring or auto
decompressor do not move smoothly. -decompressor.
The cylinder Exhaust gas leakage around cylinder Replace the damaged gasket and
compression is head. inspect cylinder head warp.
lower than the Incorrect seating surface of valve Repair seating surface if possible.
usable range.
Valve clearance is too narrow. Adjust the valve clearance.
Piston/cylinder clearance is too wide. Replace the piston and/or cylinder.
Piston seizure Inspect the cylinder and piston; repair or
replace them if necessary.
Bad condition of piston ring and/or Replace the piston and/or the piston
piston ring grooves. rings.
Auto-decompressor do not move Replace the auto-decompressor.
smoothly.
5-22 ENGINE TOP END
Cylinder Head
Cylinder Head Removal
• Drain the coolant (see Coolant Draining in the Cooling
System chapter).
• Remove:
(DFI) chapter)
moval)
Camshafts (see Camshaft Removal)
Exhaust Pipe (see Exhaust Pipe Removal)
• Remove:
Throttle Body Assy [A] (see Throttle Body Assy Removal
in the Fuel System (DFI) chapter)
Capacitor [B] (see Capacitor Removal in the Electrical
System chapter)
Ignition Coil [C] (see Ignition Coil Removal in the Elec-
trical System chapter)
Vehicle-down Sensor [D] (see Vehicle-down Sensor Re-
moval in the Fuel System (DFI) chapter)
Bracket Bolt [E]
• Disconnect:
Water Hose [F]
Water Temperature Sensor Connector [G]
• Remove:
Bolts [H] and Upper Engine Bracket [I] (Both Sides)
Clamps [J] (Open)
• Remove the cylinder head bolts (M6) [A].

• Remove thecylinder
Loosen the bolt [B].
• cylinder head bolts (M10) [C].
• Remove the cylinder head [A] upward.

NOTE
○When do not remove the cylinder head easily, tap lightly
up with a plastic mallet to separate the cylinder head
from the cylinder.
○Take care not to damage the chain guides.
NOTICE
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.
• Remove the cylinder head gasket.

ENGINE TOP END 5-23
Cylinder Head
Cylinder Head Installation
•○Install the front camshaft chain guide.
Fit the projection [A] in the groove [B] of the cylinder.
○Insert the guide end [C] into the recess of the crankcase
securely.
NOTE
○In this figure, the magneto cover and flywheel has been
removed for clarity.
• Replace the cylinder head gasket with a new one.

• Dowel Pins [A]
Install:
New Cylinder Head Gasket [B]

• Install the cylinder head.
NOTE
○The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.
• Replace the cylinder head bolts (M10) with new ones.

• areas.
Apply molybdenum disulfide oil solution to the following
Cylinder Head Bolt (M10) Washer (Both Sides) [A]

Cylinder Head Bolt (M10) Thread [B]
• Tighten the cylinder head bolts (M10) in the numbered

sequence [1 ∼ 4].
Torque - Cylinder Head Bolts (M10): 44 N·m (4.5 kgf·m, 32
ft·lb)
• Install
90° [B]
the clamps [A].
• Cylinder Bolt [C]

Tighten:
Cylinder Head Bolts (M6) [D]

Torque - Cylinder Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106
in·lb)
Cylinder Head Cleaning
• Refer to the Cylinder Head Warp Inspection in the Peri-
5-24 ENGINE TOP END
Cylinder Head
Cylinder Head Warp Inspection
• Refer to the Cylinder Head Warp Inspection in the Peri-
ENGINE TOP END 5-25
Valves
Valve Clearance Inspection
• Refer to the Valve Clearance Inspection in the Periodic
Maintenance chapter.
Valve Clearance Adjustment
• Refer to the Valve Clearance Adjustment in the Periodic
Valve Removal
• Remove the cylinder head (see Cylinder Head Removal).
• Remove the valve lifter and shim.
NOTE
○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.
• Using the valve spring compressor assembly [A] and

adapter [B], compress the valve spring and then remove
the split keepers.
Special Tools - Valve Spring Compressor Assembly: 57001
-241
Valve Spring Compressor Adapter, 22:
57001-1202
57001-1586
• Remove:
Spring Retainer
Valve Spring
Valve
Oil Seal
Spring Seat
5-26 ENGINE TOP END
Valves
Valve Installation
NOTICE
Do not lap the valve to the valve seat, using the
grinding compound. It will come off oxide film
treated surface of the valve.
• Visually inspect the valve surface.

If the surface is damaged, replace the valve.
• Replace the oil seal [A] with a new one.
• valve stem [B]coatandofinstall
Apply a thin molybdenum disulfide grease to the
the valve.
• smoothly.
Check to make sure that the valve moves up and down
• Check to make sure that the valve and valve seat are
making proper contact.
• Install:
Oil Seal
Spring Seat [C]
Valve Spring [D]
○Turn the painted side of the valve spring to the spring
retainer [E].
Exhaust - White Paint
Intake - Pink Paint
NOTE
○The flange thicknesses of the spring seats are different
in the exhaust and intake side. Take care not to install
them oppositely.
Exhaust Valve Spring Seat [F]
Intake Valve Spring Seat [G]
• Install the spring retainer.
• Compress the valve spring to install the split keepers [H]
in order to secure the spring retainer in place.
Special Tools - Valve Spring Compressor Assembly: 57001
-241
57001-1202
57001-1586
•○Install the shim to original position.
The shim [J] must be installed with its thickness indication
facing up towards the retainer.
• Apply engine oil to the valve lifter [K] surface, and install
the lifter.
ENGINE TOP END 5-27
Valves
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
Oil Seal
Spring Seat
• Heat the area around the valve guide up to 120 ∼ 150°C
(248 ∼ 302°F).
NOTICE
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
• Hammer
guide.
lightly on the valve guide arbor [A] to remove the
Special Tool - Valve Guide Arbor, 4.5: 57001-1331
Valve Guide Installation

• Apply a thin coat of engine oil to the outer surface of the
valve guide.
• Heat the area around the valve guide up to 120 ∼ 150°C
(248 ∼ 302°F).
NOTICE
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
• Using the valve guide driver [A] and attachment, press

and insert the valve guide in until the attachment bottom
surface touches the cylinder head surface [B].
Exhaust: 13.8 ∼ 14.0 mm (0.543 ∼ 0.551 in.) [C]
Intake: 15.3 ∼ 15.5 mm (0.602 ∼ 0.610 in.) [D]
Special Tools - Valve Guide Driver: 57001-1564
Valve Guide Driver Attachment, F [E]: 57001
-1722
5-28 ENGINE TOP END
Valves
• Ream the valve guide with valve guide reamer [A], even
if the old guide is reused.
○Always rotate the reamer clockwise.
Special Tool - Valve Guide Reamer, 4.5: 57001-1333
Valve/Valve Guide Clearance Measurement

(Wobble Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve/valve guide clearance
with the wobble method as indicated below.
• Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
• Move the stem back and forth [C] to measure the
valve/valve guide clearance.
• Repeat the measurement in a direction at a 90° angle to

the first measurement.
If the reading exceeds the service limit, replace the guide.
NOTE
○The reading is greater than the actual valve/valve guide
clearance because the measurement is taken outside
of the guide.
Valve/Valve Guide Clearance (Wobble Method)

Standard:
Exhaust 0.07 ∼ 0.13 mm (0.0028 ∼ 0.0051 in.)
Intake 0.02 ∼ 0.09 mm (0.0008 ∼ 0.0035 in.)
Service Limit:
Exhaust 0.30 mm (0.012 in.)
Intake 0.22 mm (0.009 in.)
ENGINE TOP END 5-29
Valves
Valve Seat Inspection
• Remove the valve (see Valve Removal).
• Check the valve seating surface [A] between the valve [B]
and valve seat [C].
• Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Exhaust 24.6 ∼ 24.8 mm (0.969 ∼ 0.976 in.)
Intake:
KX250ZD ∼ ZE 30.6 ∼ 30.8 mm (1.205 ∼ 1.213 in.)
KX250ZF 30.5 ∼ 30.7 mm (1.201 ∼ 1.209 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Exhaust 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
Intake 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
Valve Seat Repair

• For the instructions on how to use the valve seat cutter
[A], follow the operation manual provided by the tool man-
ufacturer.
Special Tools - Valve Seat Cutter Holder, 4.5 [B]: 57001
-1330
Valve Seat Cutter Holder Bar: 57001-1128
Exhaust: Valve Seat Cutter, 45° - 27.5: 57001-1114
Valve Seat Cutter, 32° - 28: 57001-1119
Intake: Valve Seat Cutter, 45° - 32: 57001-1115
If the tool manufacturer’s instructions are not available,
operate in accordance with the following procedure.
5-30 ENGINE TOP END
Valves
Seat Cutter Operation Care
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTICE
Do not use a wire brush to remove the metal par-
ticles from the cutter. It will take off the diamond
particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter Angle [B]
37.5 ....................... Cutter Outer Diameter [C]
Repair Operating Procedures

•Clean the seat area carefully.
•Coat the seat with machinist’s dye.
•Fit a 45° cutter into the holder and slide it into the valve
guide.
•Press down lightly on the handle and turn it right or left.
Grind the seating surface only until it is smooth.
NOTICE
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.
ENGINE TOP END 5-31
Valves
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
• Measure the outside diameter of the seating surface with

a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° [A] grind until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter [A] of the seating surface is too
large, make the 32° [B] grind described below.
If the outside diameter of the seating surface is within the
specified range, measure the seat width as described be-
low.
•Grind the seat at a 32° angle until the seat outside diam-
eter is within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
NOTICE
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat outside di-
ameter measurement step above.
• To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.
5-32 ENGINE TOP END
Valves
If the seat width is too wide, make the 60° [A] grind de-
scribed below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
•Grind the seat at a 60° angle until the seat width is within
the specified range [B].
○To make the 60° grind, fit a 60° cutter into the holder, and
slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° grind, return to the seat width mea-
surement step above.
NOTICE
Do not lap the valve to the valve seat, using the
grinding compound. It will come off oxide film
treated surface of the valve.
• When the engine is assembled, be sure to adjust the valve

clearance (see Valve Clearance Adjustment in the Peri-
ENGINE TOP END 5-33
Valves
5-34 ENGINE TOP END
Cylinder and Piston
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Front Camshaft Chain Guide [A]
Cylinder Bolt [B]
• Tap lightly up with a plastic mallet to separate the cylinder
[C] from the crankcase.
• Remove the cylinder base gasket.
Piston Removal
• Remove the cylinder (see Cylinder Removal).
• Remove the piston pin snap ring [A].
NOTE
○Lay a clean cloth under the piston, to prevent dropping
dirt or parts into the crankcase.
• Remove the piston pin, using a piston pin puller [A].

Special Tool - Piston Pin Puller: 57001-1568
• Remove the piston [B].
• Carefully spread the piston ring opening with your thumbs

and then push up on the opposite side of the ring [A] to
remove it.
• Remove the oil ring in the same procedure.
Cylinder and Piston Installation

NOTE
○If a new piston or cylinder is used, check piston/cylinder
clearance (see Piston/Cylinder Clearance Inspection in
the Periodic Maintenance chapter), and use new piston
rings.
ENGINE TOP END 5-35
Cylinder and Piston
NOTE
○The oil ring rails have no “top” or “bottom”.
• Install the oil ring expander [A] in the bottom piston ring
groove so the ends [B] butt together.
• Install the oil ring steel rails on both sides of the oil ring
expander.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
• Install the top ring [A] so that the “R” mark [B] faces up.
• Apply engine oil to the piston pin and inside wall of the
connecting rod small end.
• Install the piston.
Front [A]
Circle Mark [B]
• Install the piston pin.
• Fit a new piston pin snap ring into the side of the piston
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
NOTICE
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
• Replace the cylinder base gasket with a new one.

• Dowel Pins [A]
Install:
New Cylinder Base Gasket [B]

5-36 ENGINE TOP END
Cylinder and Piston
• The piston ring openings must be positioned as shown.

The openings of the oil ring steel rails must be 15 ∼ 20°
of angle from the opening of the oil ring expander.
Top Ring [A]
Upper Oil Ring Steel Rail [B]
Oil Ring Expander [C]
Lower Oil Ring Steel Rail [D]
• Apply engine oil to the cylinder bore and piston side wall.
• your fingers
Install the cylinder while compressing the piston rings with
or the special tool [A].
○Upturn the chamfering side of the belt.
Special Tools - Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt, 67 ∼ 79:
57001-1097
Cylinder Wear Inspection
• Refer to the Cylinder Wear Inspection in the Periodic
Piston Wear Inspection
• Using a micrometer, measure the outside diameter [A] of
the piston 6 mm (0.24 in.) [B] up from the bottom of the
piston at a right angle to the direction of the piston pin.
If the piston outside diameter is smaller than the service
limit, replace the piston.
Piston Diameter
Standard: 76.948 ∼ 76.963 mm (3.0294 ∼ 3.0300 in.)
Piston/Cylinder Clearance Inspection

• Refer to the Piston/Cylinder Clearance in the Periodic
Piston Ring/Ring Groove Clearance Inspection
• Check
ing.
for uneven groove wear by inspecting the ring seat-
The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all piston rings.
• With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Ring Groove Clearance
Standard:
Top 0.04 ∼ 0.08 mm (0.002 ∼ 0.003 in.)
Service Limit:
Top 0.18 mm (0.0071 in.)
If the piston ring groove clearance is greater than the ser-
vice limit, measure the ring thickness and groove width as
follows to decide whether to replace the rings, the piston
or both.
ENGINE TOP END 5-37
Cylinder and Piston
Piston Ring Groove Width Inspection
• Measure the groove width at several points around the
piston with a vernier caliper.
Piston Ring Groove Width
Standard:
Top 0.83 ∼ 0.85 mm (0.0327 ∼ 0.0335 in.)
Service Limit:
Top 0.93 mm (0.037 in.)
If any of the groove widths exceeds the service limit, re-
place the piston.
Piston Ring Thickness Inspection
• Measure the thickness at several points around the ring
with a micrometer.
Piston Ring Thickness
Standard:
Top 0.77 ∼ 0.79 mm (0.030 ∼ 0.031 in.)
Service Limit:
Top 0.70 mm (0.028 in.)
If any of the measurements is less than the service limit,
replace all rings.
NOTE
○When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
Piston Ring End Gap Measurement

• Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.
• Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top 0.15 ∼ 0.25 mm (0.0059 ∼ 0.0098 in.)
Oil 0.20 ∼ 0.70 mm (0.0079 ∼ 0.0276 in.)
Service Limit:
Top 0.6 mm (0.02 in.)
Oil 1.0 mm (0.04 in.)
If the ring end gap exceeds the service limit, replace all
rings.
5-38 ENGINE TOP END
Cylinder and Piston
Piston, Piston Pin, Connecting Rod Wear
Inspection
• Visually inspect the snap rings [A] still fitted in place.
If the ring shows weakness or deformation, replace the
ring. Also if the pin hole groove shows excessive wear,
replace the piston.
• Measure the diameter of the piston pin [B] with a microm-
eter.
Piston Pin Diameter
Standard: 15.991 ∼ 16.000 mm (0.62957 ∼ 0.62992
in.)
If the piston pin diameter is less than the service limit at
any point, replace the piston pin.
• Using a cylinder gauge, measure the diameter of both
piston pin holes [C] in the piston and the inside diameter
of the connecting rod small end [D].
Piston Pin Hole Diameter
Standard: 16.004 ∼ 16.010 mm (0.63008 ∼ 0.63031
in.)
Connecting Rod Small End Inside Diameter

Standard: 16.010 ∼ 16.018 mm (0.63031 ∼ 0.63063
in.)
If either piston pin hole diameter exceeds the service limit,
replace the piston.
If the connecting rod small end inside diameter exceeds
the service limit, replace the connecting rod.
ENGINE TOP END 5-39
Throttle Body Assy Holder
Throttle Body Assy Holder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Throttle Body Assy Holder Clamp Screw [A] (Loosen)
Throttle Body Assy Holder [B] and Holder Clamp
Throttle Body Assy Holder Installation

• Install:
Throttle Body Assy Holder
Throttle Body Assy Holder Clamp
○Turn the mark [A] to the throttle body assy.
○Turn the screw head [B] to the engine left side.
○Fit the projection [C] of the cylinder head and the recess
[D] of the holder.
• Tighten:
Torque - Throttle Body Holder Clamp Screw: 2.0 N·m (0.20
kgf·m, 18 in·lb)
5-40 ENGINE TOP END
Muffler
WARNING
The muffler can become extremely hot during nor-
mal operation and cause severe burns. Do not re-
move the muffler while it is hot.
Muffler Body Removal

• Remove the right side cover (see Side Cover Removal in
the Frame chapter).
• Loosen the muffler clamp bolt [A].
• body [C] the
Remove mounting bolts [B], and pull out the muffler
backward.
Exhaust Pipe Removal

• Remove:
Muffler Body (see Muffler Body Removal)
Exhaust Pipe Holder Nuts [A]
Exhaust Pipe [B]
Muffler Installation
• Replace the exhaust pipe gasket and muffler pipe gasket
with new ones.
• Apply grease to the exhaust pipe gasket, and install it to
the engine.
• Install the gasket to the muffler pipe until it is bottomed.
• temporary.
Install the exhaust pipe, muffler body and muffler clamp
○Turn the punch mark [A] of the exhaust pipe holder to right
side of the motorcycle.
○Tighten the exhaust pipe holder nuts first, and then the
muffler mounting bolt (rear).
•Tighten the muffler mounting bolts securely.
○Tighten the front bolt first, and then the rear bolt.
•Tighten the exhaust pipe holder nuts securely.
•Upturn the muffler clamp opening and fit the hole [B] of
the muffler clamp to the projection [C] of the muffler body.
•Tighten the muffler clamp bolt securely.
•Thoroughly warm up the engine, wait until the engine
cools down, and then retighten all bolts and nuts.
Silencer Wool Replacement

• Refer to the Silencer Wool Replacement in the Periodic
CLUTCH 6-1
Clutch
Table of Contents
Exploded View........................................................................................................................ 6-2
Specifications ......................................................................................................................... 6-4
Special Tools .......................................................................................................................... 6-5
Clutch Lever and Cable .......................................................................................................... 6-6
Clutch Lever (Clutch Cable) Free Play Inspection ............................................................ 6-6
Clutch Lever (Clutch Cable) Free Play Adjustment .......................................................... 6-6
Clutch Lever Installation.................................................................................................... 6-6
Clutch Cable Removal ...................................................................................................... 6-6
Clutch Cable Installation ................................................................................................... 6-7
Clutch Cable Inspection and Lubrication .......................................................................... 6-7
Clutch Cover and Right Engine Cover.................................................................................... 6-8 6
Clutch Cover Removal ...................................................................................................... 6-8
Clutch Cover Installation ................................................................................................... 6-8
Right Engine Cover Removal............................................................................................ 6-8
Right Engine Cover Installation......................................................................................... 6-9
Right Engine Cover Assembly .......................................................................................... 6-10
Clutch ..................................................................................................................................... 6-11
Clutch Removal................................................................................................................. 6-11
Clutch Installation.............................................................................................................. 6-11
Release Shaft Removal .................................................................................................... 6-14
Release Shaft Installation ................................................................................................. 6-14
Clutch Plates Wear, Damage Inspection .......................................................................... 6-14
Clutch Plates Warp Inspection .......................................................................................... 6-14
Clutch Spring Free Length Inspection............................................................................... 6-14
Clutch Housing Finger Damage Inspection ...................................................................... 6-14
Friction Plate/Clutch Housing Clearance Inspection......................................................... 6-15
Clutch Hub Spline Damage Inspection ............................................................................. 6-15
6-2 CLUTCH
Exploded View
CLUTCH 6-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Right Engine Cover Bolts 9.8 1.0 87 in·lb
2 Clutch Cover Bolts 9.8 1.0 87 in·lb
3 Oil Filler Plug 3.5 0.36 31 in·lb
4 Clutch Hub Nut 98 10.0 72 R
5 Clutch Spring Bolts 9.0 0.92 80 in·lb
6. Circlip Equipped Models
CL: Apply cable lubricant.
G: Apply grease.
6-4 CLUTCH
Specifications

Clutch Lever
Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – –
Clutch
Friction Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.5 mm (0.10 in.)
Friction Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
Clutch Spring Free Length 45.82 mm (1.804 in.) 43.9 mm (1.73 in.)
Friction Plate/Clutch Housing 0.04 ∼ 0.55 mm (0.002 ∼ 0.022 in.) 0.6 mm (0.02 in.)
Clearance
CLUTCH 6-5
Special Tools
Inside Circlip Pliers: Clutch Holder:
57001-143 57001-1243
Bearing Driver Set:

57001-1129
6-6 CLUTCH
Clutch Lever and Cable
Due to friction plate wear and clutch cable stretch over
a long period of use, the clutch must be adjusted in accor-
dance with the Periodic Maintenance Chart.
WARNING
The engine and exhaust system get extremely hot
during normal operation and can cause serious
burns. Never touch the engine or exhaust pipe
during clutch adjustment.
Clutch Lever (Clutch Cable) Free Play Inspection

• Refer to the Clutch Operation Inspection in the Periodic
Clutch Lever (Clutch Cable) Free Play Adjustment
• Refer to the Clutch Operation Inspection in the Periodic
Clutch Lever Installation
• Install the clutch lever assembly [A].
25 ∼ 35° [B]
Horizontal Line of Frame [C]
160.5 mm (6.32 in.) [D]
Clutch Cable Removal

• Remove:
chapter)
the Frame chapter)
Left Radiator Screen (see Radiator Removal in the Cool-
ing System chapter)
• Loosen the locknut [B] and screw in the adjuster [C] fully.
• Slide the dust cover [A] and knob [B] out of place.
CLUTCH 6-7
Clutch Lever and Cable
• Align the slit [A] of the adjusting nut to the slit [B] of the
clutch lever.
• Free the clutch cable upper end from the clutch lever.
• Take the cable off the cable holder [A].

• [C]. the cable lower end [B] off the clutch release lever
Take
NOTICE
Do not remove the clutch release shaft unless it is
absolutely necessary. If removed, release shaft oil
seal must be replaced with a new one.
• Open the clamps [A].

• Pull the clutch cable out of the frame.
Clutch Cable Installation

• Apply grease to the lips [A] of adjusting nut.
• Routing clutch
Run the cable correctly (see Cable, Wire, and Hose
section in the Appendix chapter).
• Adjust the clutch cable (see Clutch Operation Inspection
Clutch Cable Inspection and Lubrication

• During a periodic inspection or when the cable has been
removed, inspect and lubricate the cable (see General
Lubrication and Cable Inspection section in the Periodic
6-8 CLUTCH
Clutch Cover and Right Engine Cover
Clutch Cover Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
• Remove:
Brake Pedal Bolt [A]
Brake Pedal Return Spring [B]
• Remove the clutch cover bolts [A] and clutch cover [B].
Clutch Cover Installation

• Replace the clutch cover gasket with a new one.
• Install the clutch cover and new cover gasket.
• L = 65 mm (2.6 in.) [A]
Tighten:
L = 25 mm (1.0 in.) [B]

Torque - Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Right Engine Cover Removal

• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Coolant (see Coolant Draining in the Cooling System
chapter)
• Remove:
Kick Pedal (see Kick Pedal Removal in the Crank-
Oil Filter (see Oil Filter Change in the Periodic Mainte-
nance chapter)
CLUTCH 6-9
• Remove:
Bolt [A]
Right Engine Guard [B]
• Remove:
Water Pump Cover (see Water Pump Cover Removal in
the Cooling System chapter)
Clutch Cover Bolts [A]
Right Engine Cover Bolts [B]
Right Engine Cover [C]
Right Engine Cover Installation

• Install the dowel pins [A].
• Replace the right engine cover gasket [B] with a new one.
• prevent damage.
Wrap the spline [C] of the kick shaft with the vinyl tape to
• Apply grease to the kick shaft oil seal lip.
• When installing the cover does not go well, the cover is

installed according to the following procedures.
○Install the cover while turning the impeller [A].
• Tighten:
L = 35 mm (1.4 in.) [A]
L = 25 mm (1.0 in.) [B]
Torque - Right Engine Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
6-10 CLUTCH
• Remove the vinyl tape from the kick shaft.

• Water Pump Cover (see Water Pump Cover Installation
Install:
in the Cooling System chapter)

Brake Pedal (see Brake Pedal Installation in the Brakes
chapter)
Oil Filter (see Oil Filter Change in the Periodic Mainte-
nance chapter)
Kick Pedal (see Kick Pedal Installation in the Crank-
• Pour:
tenance chapter)
Coolant (see Coolant Filling in the Cooling System chap-
ter)
• Check the rear brake effectiveness (see Brakes section
Right Engine Cover Assembly
• Refer to the Oil Seal and Bearing Installation in the Cool-
ing System chapter for water pump oil seals and bearing
installation.
• Replace the removed oil seal and circlip with new ones.
• Press in the oil seals direction as shown.
○Press in the new oil seal using a press and suitable tools
so that the seal surface is flush with the surface of the
right engine cover.
Flat Side [A]
Kick Shaft Oil Seal [B]
○Press the new crankshaft oil passage oil seal [A] so that
the seal surface is flush with the surface of the right engine
cover.
Flat Side [B]
○Install the new circlip [C].
• Apply grease to the oil seal lips.
CLUTCH 6-11
Clutch
Clutch Removal
• Remove:
Clutch Cover (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs
Clutch Spring Plate [B]
• Remove:
Push Rod Holder Assembly [A]
Steel Ball
Friction Plates [B]
Steel Plates [C]
• Hold the clutch hub [A] with the clutch holder [B].
Special Tool - Clutch Holder: 57001-1243
• Remove:
Clutch Hub Nut [C]
Toothed Washer [D]
Clutch Hub
Thrust Washer
Clutch Housing [E]
• Remove:
Needle Bearing [A]
Sleeve [B]
Clutch Installation
• Apply molybdenum disulfide oil solution to the outside of
the sleeve [A].
• Install the sleeve so that the flange [B] faces inside.
• Install the needle bearing [C].
6-12 CLUTCH
Clutch
•○Install the clutch housing [A].

Turn the kickstarter idle gear and oil pump idle gear with
a suitable tool [B] to fit in the clutch housing.
• Install:
Thrust Washer [A]
Clutch Hub [B]
• Hold the clutch hub with the clutch holder [A].

Special Tool - Clutch Holder: 57001-1243
• Install the toothed washer [B].
•○Turn the the
Replace clutch hub nut [C] with a new one.
large chamfering side of the clutch hub nut to
outside.
• Tighten:
Torque - Clutch Hub Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
•○Install the friction plates and steel plates alternately.

Install the friction plate first.
NOTICE
If new dry steel plates and friction plates are in-
stalled, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
• Apply molybdenum disulfide grease to the rubbing portion

[A] of push rod holder, steel ball [B] and washers [C].
• Install the steel ball and push rod holder assembly.
CLUTCH 6-13
Clutch
• Ifwasher
a clutch part was replaced, install the standard adjusting
(1.5 mm thickness) [A] of the push rod holder as-
sembly, and check the release lever position as explained
later procedure.
• Install the clutch spring plate and clutch springs.

• housing the
Tighten clutch spring bolts while holding the clutch
with the hand.
Torque - Clutch Spring Bolts: 9.0 N·m (0.92 kgf·m, 80 in·lb)
• Check the release shaft lever position.

• measure [A]
Pushing the release shaft lever [B] lightly forward,
the distance [C] between the release shaft lever
and bracket [D].
Release Shaft Lever Position
Standard: 49.2 ∼ 56.5 mm (1.94 ∼ 2.22 in.)
If the lever position is not within the standard, select the
correct thickness of adjusting washer(s) according to the
tables shown.
Adjusting Washers
Thickness Part Number
1.5 mm (0.06 in.) 92200-1548
1.0 mm (0.04 in.) 92200-0045
Release Shaft Lever Position and Adjusting Washer

Selection
Washers
Position Distance Judgment Qty
Thickness
49.2 ∼ 56.5 mm (1.94
Standard 1.5 mm (0.06 in.) 1
∼ 2.22 in.)
More than 56.5 mm
Too big 1.0 mm (0.04 in.) 1
(2.22 in.)
Less than 49.2 mm
Too small 1.0 mm (0.04 in.) 2
(1.94 in.)
Remove the push rod holder assembly as necessary and
reinstall the clutch.
6-14 CLUTCH
Clutch
Release Shaft Removal
• Remove:
Clutch (see Clutch Removal)
Clutch Cable Upper End (see Clutch Cable Removal)
• Remove the tip [A] of the clutch cable.
• Pull out the release shaft assembly [B].
Release Shaft Installation

• Apply engine oil to the needle bearings [A].
• Replace the oil seal [B] with a new one (see Crankcase
Assembly in the Crankshaft/Transmission chapter).
• Apply grease to the release shaft lower end [C] and oil
seal lips.
• Insert the release shaft straight into the upper hole of the
crankcase.
NOTICE
When inserting the release shaft, be careful not to
remove the spring of the oil seal.

Clutch Plates Wear, Damage Inspection
• Refer to the Clutch Plates Inspection in the Periodic Main-
tenance chapter.
Clutch Plates Warp Inspection
• Refer to the Clutch Plates Inspection in the Periodic Main-
tenance chapter.
Clutch Spring Free Length Inspection
• Measure the free length [A] of the clutch springs.
If any clutch spring is shorter than the service limit, it must
be replaced.
Clutch Spring Free Length
Standard: 45.82 mm (1.804 in.)
Clutch Housing Finger Damage Inspection

• Visually inspect the clutch housing fingers [A] that come
in contact with the friction plate tangs.
If they are damaged or if there are groove cuts in the areas
that come in contact with the tangs, replace the housing.
Replace the friction plates if their tangs are damaged as
well.
CLUTCH 6-15
Clutch
Friction Plate/Clutch Housing Clearance
Inspection
• Measure the clearance between the tangs [A] on the fric-
tion plate and the fingers [B] of the clutch housing.
If this clearance is excessive, the clutch will be noisy.
If the clearance exceeds the service limit, replace the fric-
tion plates.
Friction Plate/Clutch Housing Clearance
Standard: 0.04 ∼ 0.55 mm (0.002 ∼ 0.022 in.)
Clutch Hub Spline Damage Inspection

• Visually inspect the areas of the clutch hub splines that
come in contact with the teeth of the steel plates.
If there are notches worn into the clutch hub splines [A],
replace the clutch hub. Replace the steel plates if their
teeth are damaged as well.
ENGINE LUBRICATION SYSTEM 7-1

Table of Contents
Exploded View........................................................................................................................ 7-2
Lubrication System Chart ....................................................................................................... 7-4
Specifications ......................................................................................................................... 7-6
Special Tools .......................................................................................................................... 7-7
Engine Oil and Oil Filter.......................................................................................................... 7-8
Engine Oil Level Inspection .............................................................................................. 7-8
Engine Oil Change............................................................................................................ 7-8
Oil Filter Replacement ...................................................................................................... 7-9
Oil Screen Cleaning and Inspection.................................................................................. 7-9
Oil Pump................................................................................................................................. 7-11
Oil Pump Removal ............................................................................................................ 7-11
Oil Pump Installation ......................................................................................................... 7-12
Oil Pump Inspection.......................................................................................................... 7-13 7
Oil Pressure............................................................................................................................ 7-14
Oil Pressure Measurement ............................................................................................... 7-14
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Oil Filter Cap Bolts 9.8 1.0 87 in·lb
2 Piston Oil Nozzle 2.9 0.30 26 in·lb
3 Breather Fitting 15 1.5 11
4 Oil Pump Idle Gear Shaft Screws 5.9 0.60 52 in·lb L
5 Oil Pump Mounting Bolts 7.0 0.71 62 in·lb L
6 Engine Oil Drain Bolt 20 2.0 15
G: Apply grease.
Lubrication System Chart
Lubrication System Chart
1. Oil Screen (Scavenge)
2. Oil Shower to Transmission
3. Piston Oil Nozzle
4. Breather Hose
5. Oil Filter
6. Oil Screen (Feed)
7. Oil Pump (Scavenge)
8. Oil Pump (Feed)
9. Kick Starter Idle Gear
A: Crank Room Oil
B: Transmission Room Oil
C: Blowby Gas
D: Engine Oil
Specifications
Item Standard
Engine Oil
Type Castrol “POWER1 Racing 4T” 5W-40 or
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity SAE 10W-30, 10W-40, or 10W-50
Capacity 0.75 L (0.79 US qt) (when filter is not removed)
0.80 L (0.85 US qt) (when filter is removed)
1.00 L (1.06 US qt) (when engine is completely dry)
Oil Level Between upper and lower level lines (after warm-up or driving)
Oil Pressure Measurement
Oil Pressure About 98 kPa (1.0 kgf/cm², 14.2 psi) at 4 000 r/min (rpm), Oil
Temperature 40°C (104°F)
Special Tools
Oil Pressure Gauge, 5 kgf/cm²: Oil Pressure Gauge Adapter, M6 × 1.0:
57001-125 57001-1664
Outside Circlip Pliers:

57001-144
Engine Oil and Oil Filter
WARNING
Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.
The engine oil level indicated in the oil level inspection
window is very sensitive to the motorcycle’s position and
engine rpm at time of shut down. Because of the semi-dry
sump lubrication system with separate oil chambers in the
crank room and transmission room, under certain condi-
tions oil can accumulate in the crank room and give a false
low reading at the oil level inspection window, which indi-
cates oil volume in the transmission room.
Engine Oil Level Inspection
• Situate the motorcycle so that it is vertical.
• and lower [B]thelevels
Check that engine oil level is between the upper [A]
in the inspection window [C].
NOTE
○If the motorcycle has just been used, wait several min-
utes for all the oil to drain down.
○If no oil appears in the inspection window, tip the motor-
cycle slightly to the right until oil is visible then return to
an upright position. If no oil appears even when tipped
at an extreme angle, remove the drain bolt to empty
any oil, reinstall the drain bolt and refill with the speci-
fied amount of oil.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil.
○ not run the engine at high engine speed. Stop the
Do
engine, then wait several minutes until the oil settles.
NOTICE
Racing the engine before the oil reaches every part
can cause engine seizure.
If the oil level is too high, remove the excess oil through
the filler opening, using a syringe or some other suitable
device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.
NOTE
○If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level rather than
running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Engine Oil Change
• Refer to the Engine Oil Change in the Periodic Mainte-
nance chapter.
Oil Filter Replacement
• Refer to the Oil Filter Replacement in the Periodic Main-
tenance chapter.
Oil Screen Cleaning and Inspection
Oil Screen (Feed)
•Split the crankcase (see Crankcase Disassembly in the
Crankshaft/Transmission chapter).
•Remove the oil screen (feed) [A].
Left Crankcase [B]
• Clean the oil screen with a high flash-point solvent and

remove any particles stuck to them.
WARNING
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the screen.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
• Check the screen (feed) [A] carefully for any damage,

holes, broken wires or gasket pulling off.
If the screen is damaged, replace it with a new one.
• Install the oil screen (feed) [A].

Projection [B]
Left Crankcase [C]
• Assemble the crankcase (see Crankcase Assembly in the
Crankshaft/Transmission chapter).
Oil Screen (Scavenge)
•Remove the magneto cover (see Magneto Cover Re-
moval in the Electrical System chapter).
•Remove the oil screen (scavenge) [A].
• Clean the oil screen with a high flash-point solvent and

remove any particles stuck to them.
WARNING
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the screen.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
• Check the oil screen (scavenge) [A] carefully for any dam-
age, holes, broken wires or gasket pulling off.
If the screen is damaged, replace it with a new one.
• Apply engine oil to the three sides [A] of screen.

• NarrowtheSide
Install oil screen (scavenge).
[B]
• in the Electrical System
Install the magneto cover (see Magneto Cover Installation
chapter).
Oil Pump
Oil Pump Removal
• Drain:
tenance chapter)
chapter)
• Remove:
Brake Pedal (see Brake Pedal Removal in the Brakes
chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Primary Gear (see Primary Gear Removal in the Crank-
• Remove:
Circlip [A]
Oil Pump Idle Gear [B]
Special Tool - Outside Circlip Pliers: 57001-144
• Remove:
Oil Pump Mounting Bolts [A]
Oil Pump Assembly [B]
• Remove:
Inner [A] and Outer [B] Rotors (Scavenge)
Dowel Pin [C]
Pin [D]
Oil Pump
• Disassemble
Pins [A]
the oil pump assembly.
Oil Pump Cover [B]

Inner [C] and Outer [D] Rotors (Feed)
Oil Pump Body [E]
Oil Pump Gear [F]
Oil Pump Installation

• Apply molybdenum disulfide grease to the shaft of the oil
pump gear.
• Apply engine oil to the inner and outer rotors.
• Oil Pump Body [A]
Assemble:
Gear [B]
Pin [C]
Inner Rotor (Feed) [D]
○ the slot [E] of the inner rotor onto the pin.
Fit
• Install:
Outer Rotor (Feed) [A]
Cover [B]
• Install:
Pin [A]
Inner Rotor (Scavenge) [B]
○Fit the slot [C] of the inner rotor onto the pin.
• Install:
Outer Rotor (Scavenge) [A]
Pin [B]
Dowel Pin [C]
Oil Pump Assembly
• Apply a non-permanent locking agent to the oil pump
mounting bolts.
• Tighten:
Torque - Oil Pump Mounting Bolts: 7.0 N·m (0.71 kgf·m, 62
in·lb)
Oil Pump
• Apply molybdenum disulfide grease to the shaft of the oil

pump idle gear [A].
• Install the oil pump idle gear.
• operatesthe
Turn [B] oil pump idle gear to check that the oil pump
smoothly.
• Replace the circlip [C] with a new one.
• Install the new circlip.
Oil Pump Inspection
• Disassemble
moval).
the oil pump assembly (see Oil Pump Re-
• Visually inspect the oil pump body, outer rotors and the
inner rotors.
If the oil pump is any damage or uneven wear, replace the
rotors, cover, body, or the crankcase.
Oil Pressure
Oil Pressure Measurement
• Remove the water pump cover bolt.
• Install the oil pressure gauge adapter [A] to the water
pump cover.
Special Tool - Oil Pressure Gauge Adapter, M6 × 1.0:
57001-1664
• Attach the oil pressure gauge [A].

Special Tool - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
• Start the engine.
NOTE
○Warm up the engine thoroughly before measuring the
oil pressure.
• Run the engine at the specified speed, and read the oil
pressure gauge.
Oil Pressure
Standard: About 98 kPa (1.0 kgf/cm², 14.2 psi) at
4 000 r/min (rpm), Oil Temperature 40°C
(104°F)
If the reading is much lower than the standard, check the
feed oil pump and crankshaft oil seal.
If the reading is much higher than the standard, check the
oil filter first, and oil passages for dirt or clogging.
• Stop the engine and remove the gauge and oil pressure
gauge adapter.
WARNING
Hot oil can cause severe burns. Beware of hot en-
gine oil that will drain through the oil passage when
the gauge adapter is removed.
• Replace
one.
the water pump cover bolt washer with a new
• Install the water pump cover bolt and new washer.

• Tighten:
Torque - Water Pump Cover Bolt: 9.8 N·m (1.0 kgf·m, 87
in·lb)
ENGINE REMOVAL/INSTALLATION 8-1
Table of Contents
Exploded View........................................................................................................................ 8-2
Special Tools .......................................................................................................................... 8-4
Engine Removal/Installation ................................................................................................... 8-5
Engine Removal................................................................................................................ 8-5
Engine Installation............................................................................................................. 8-7
8
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Upper Engine Mounting Bolts 49 5.0 36 S
2 Upper Engine Bracket Bolts 29 3.0 21 S
3 Middle Engine Bracket Nuts 29 3.0 21 R, S
4 Middle Engine Mounting Nut 49 5.0 36 R, S
5 Lower Engine Mounting Nut 49 5.0 36 R, S
6 Swingarm Pivot Shaft Nut 98 10.0 72 R, S
Special Tools
57001-1238 57001-1608
Engine Removal
• Remove the engine guards.
• Place the jack under the frame to support the motorcycle.
WARNING
When the swingarm pivot shaft is removed the
swingarm and rear wheel assembly will become
detached and allow the frame to fall to the floor,
creating the potential for injury. Removing the
engine requires the swingarm pivot to be removed,
so support the bottom of the frame with a jack or
other appropriate stand.
• Squeeze
[A].
the brake lever slowly and hold it with a band
WARNING
Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the engine.
NOTICE
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.
• Drain:
tenance chapter)
chapter)
• Remove:
Rear Frame (see Rear Frame Removal in the Frame
chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
(DFI) chapter)
Radiators and Water Hoses (see Radiator Removal in
the Cooling System chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Ignition Coil (see Ignition Coil Removal in the Electrical
System chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
Clutch Cable Lower End (see Clutch Cable Removal in
the Clutch chapter)
Brake Pedal Bolt and Return Spring (see Brake Pedal
Removal in the Brakes chapter)
• Disconnect:
Gear Position Switch Lead Connector [A]
Magneto Lead Connector [B]
• Remove the bolt [C].
• Remove the vehicle-down sensor bracket bolts [A].

• Disconnect the water temperature sensor connector [A].

• Upper Engine
Remove the following parts on both sides:
Bracket Bolts [B]
Upper Engine Mounting Bolts [C] and Nuts
Upper Engine Brackets [D]
• Remove:
Middle Engine Bracket Bolts [A] and Nuts
Middle Engine Mounting Bolt [B] and Nut
Middle Engine Bracket [C] (Both Sides)
Lower Engine Mounting Bolt [D] and Nut
• Remove:
Swingarm Pivot Shaft Nut [A]
Swingarm Pivot Shaft [B]
•○Remove the engine from the motorcycle to right side.

Clear the engine rear portion from the swingarm and then
remove the engine.
Engine Installation
• Replace with new ones:
Upper Engine Mounting Nuts
Middle Engine Mounting Nut
Middle Engine Bracket Nuts
Lower Engine Mounting Nut
•Install the engine.
○First, insert the front portion of the engine from the right
side, and then install the rear portion.
○Second, fit the rear portion of the engine to the swingarm.
• Insert the swingarm pivot shaft from the right side.

•○Insert the
Install all engine brackets, bolts and nuts temporarily.
following bolts from left side:
Middle Engine Mounting Bolt [A]
Middle Engine Bracket Bolts [B]
Lower Engine Mounting Bolt [C]
• Install the swingarm pivot shaft nut with the washer.

• ∼ 6]. the bolts and nuts in the numbered sequence [1
Tighten
Torque - Swingarm Pivot Shaft Nut [1]: 98 N·m (10.0 kgf·m,

72 ft·lb)
Lower Engine Mounting Nut [2]: 49 N·m (5.0 kgf·m,
36 ft·lb)
Middle Engine Mounting Nut [3]: 49 N·m (5.0
kgf·m, 36 ft·lb)
Middle Engine Bracket Nuts [4]: 29 N·m (3.0 kgf·m,
21 ft·lb)
Upper Engine Bracket Bolts [5]: 29 N·m (3.0 kgf·m,
21 ft·lb)
Upper Engine Mounting Bolts [6]: 49 N·m (5.0
kgf·m, 36 ft·lb)

• Wire, andcables,
Run the hoses, and leads according to the Cable,
Hose Routing section in the Appendix chapter.
• Pour:
tenance chapter)
Coolant (see Coolant Filling in the Cooling System chap-
ter)
• Adjust:
Throttle Cable (see Throttle Grip Free Play Adjustment
in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Operation Inspection in the Pe-
riodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Adjustment in the
Periodic Maintenance chapter)
Idle Speed (see Idle Speed Adjustment in the Periodic
• Check the brake effectiveness.
WARNING
After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.
CRANKSHAFT/TRANSMISSION 9-1
Table of Contents
Exploded View........................................................................................................................ 9-2
Specifications ......................................................................................................................... 9-8
Crankcase .............................................................................................................................. 9-10
Crankcase Disassembly ................................................................................................... 9-10
Crankcase Assembly ........................................................................................................ 9-11
Crankshaft .............................................................................................................................. 9-17
Crankshaft Removal ......................................................................................................... 9-17
Crankshaft Installation ...................................................................................................... 9-17
Crankshaft Disassembly ................................................................................................... 9-17
Crankshaft Assembly ........................................................................................................ 9-17
Crankshaft Inspection ....................................................................................................... 9-18
Connecting Rod Bend Inspection ..................................................................................... 9-20
Connecting Rod Twist Inspection...................................................................................... 9-20
Transmission .......................................................................................................................... 9-21
Transmission Shaft Removal ............................................................................................ 9-21
Transmission Shaft Installation ......................................................................................... 9-21
Transmission Shaft Disassembly ...................................................................................... 9-21
9
Transmission Shaft Assembly........................................................................................... 9-22
Shift Fork Bending Inspection ........................................................................................... 9-24
Shift Fork/Gear Groove Wear Inspection.......................................................................... 9-25
Shift Fork Guide Pin/Shift Drum Groove Wear Inspection ................................................ 9-25
Gear Damage Inspection .................................................................................................. 9-25
Primary Gear .......................................................................................................................... 9-26
Primary Gear Removal ..................................................................................................... 9-26
Primary Gear Installation .................................................................................................. 9-26
External Shift Mechanism....................................................................................................... 9-27
Shift Pedal Removal ......................................................................................................... 9-27
Shift Pedal Installation ...................................................................................................... 9-27
External Shift Mechanism Removal .................................................................................. 9-27
External Shift Mechanism Installation ............................................................................... 9-28
External Shift Mechanism Inspection................................................................................ 9-29
Kickstarter............................................................................................................................... 9-31
Kick Pedal Removal.......................................................................................................... 9-31
Kick Pedal Installation....................................................................................................... 9-31
Kick Pedal Disassembly.................................................................................................... 9-31
Kick Pedal Assembly ........................................................................................................ 9-31
Kick Shaft Removal........................................................................................................... 9-32
Kick Shaft Installation........................................................................................................ 9-32
Kick Shaft Assembly Disassembly/Assembly ................................................................... 9-32
Bearings/Oil Seals .................................................................................................................. 9-34
Bearing Replacement ....................................................................................................... 9-34
Bearing Wear Inspection................................................................................................... 9-34
Oil Seal Inspection ............................................................................................................ 9-35
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
KX250ZD
Exploded View
Torque
N·m kgf·m ft·lb
1 Primary Gear Nut 98 10.0 72 Lh, R
2 Reed Valve Screws 7.0 0.71 62 in·lb
3 Crankcase Bearing Retainer Screws 15 1.5 11 L
5 Crankcase Bolts (L = 50 mm) 9.8 1.0 87 in·lb S
6 Crankcase Bolt (L = 65 mm) 9.8 1.0 87 in·lb S
G: Apply grease.
Exploded View
KX250ZE ∼
Exploded View
Torque
N·m kgf·m ft·lb
1 Primary Gear Nut 98 10.0 72 Lh, R
2 Reed Valve Screws 7.0 0.71 62 in·lb
3 Crankcase Bearing Retainer Screws 15 1.5 11 L
6 Crankcase Bolt (L = 65 mm) 9.8 1.0 87 in·lb S
G: Apply grease.
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Kick Ratchet Guide Bolt 8.8 0.90 78 in·lb L
2 Kick Pedal Bolt 25 2.5 18 L
3 Shift Drum Cam Bolt 24 2.4 18 L
4 Gear Positioning Lever Nut 8.8 0.90 78 in·lb
5 Ratchet Plate Bolt 9.8 1.0 87 in·lb L, S
6 Ratchet Plate Screw 15 1.5 11 L, S
7 Shift Pedal Bolt 9.8 1.0 87 in·lb
G: Apply grease.
St: Stake the fasteners to prevent loosening.
Specifications

Crankshaft, Connecting Rod
Connecting Rod Big End:
Radial Clearance 0.002 ∼ 0.014 mm 0.06 mm (0.0024 in.)
(0.00008 ∼ 0.00055 in.)
Side Clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) 0.6 mm (0.02 in.)
Crankshaft Runout TIR 0.03 mm (0.001 in.) or less TIR 0.08 mm (0.003 in.)
Connecting Rod Bend ––– TIR 0.2/100 mm
(0.008/3.94 in.)
Connecting Rod Twist ––– TIR 0.2/100 mm
(0.008/3.94 in.)
Transmission
Shift Fork Ear Thickness 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) 4.8 mm (0.189 in.)
Gear Groove Width 5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.) 5.3 mm (0.209 in.)
Shift Fork Guide Pin Diameter 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.) 5.8 mm (0.228 in.)
Shift Drum Groove Width 6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.) 6.3 mm (0.25 in.)
Bearing Puller: Crankcase Splitting Tool Assembly:
57001-135 57001-1362
Outside Circlip Pliers: Gear Holder, m2.0:

57001-144 57001-1557
Bearing Driver Set: Liquid Gasket, TB1216:

57001-1129 92104-1063
Crankshaft Jig:
57001-1174
Crankcase
Crankcase Disassembly
• Remove the engine from the frame (see Engine Removal
in the Engine Removal/Installation chapter).
• Set the engine on clean surface while parts are being re-
moved.
• Remove:
Piston (see Piston Removal in the Engine Top End chap-
ter)
Primary Gear (see Primary Gear Removal)
Oil Pumps (see Oil Pump Removal in the Engine Lubri-
cation System chapter)
Kick Shaft (see Kick Shaft Removal)
External Shift Mechanism (see External Shift Mecha-
nism Removal)
Flywheel (see Flywheel Removal in the Electrical Sys-
tem chapter)
Gear Position Switch (see Gear Position Switch Re-
moval in the Fuel System (DFI) chapter)
• Slide out the clamp [A], and remove the breather hose [B].
• Remove the output shaft collar [A] and O-rings.

• Remove the crankcase bolts [B].
• Position the connecting rod in BDC.

• wheels. crankshaft jig [A] between the crankshaft fly-
Install the
Special Tool - Crankshaft Jig: 57001-1174

Crankcase
• Attach the
crankcase.
crankcase splitting tool [A] to the left
○Adjust the gap with suitable collars or nuts [B].

Special Tool - Crankcase Splitting Tool Assembly: 57001
-1362
•○Tighten the center bolt to split the crankcase halves.
The front and rear portion of the crankcase must be pulled
apart evenly.
• Remove:
Oil Screen (Feed) (see Oil Screen Cleaning and Inspec-
tion in the Engine Lubrication System chapter)
Shift Rods [A]
Shift Forks [B]
Shift Drum [C] (see Transmission Shaft Removal)
Transmission Shafts [D] (see Transmission Shaft Re-
moval)
Crankshaft [E] (see Crankshaft Removal)
NOTICE
Do not remove the bearings and the oil seals unless
it is necessary. Removal may damage them.
•○Remove the reed valve [A] from the left crankcase half.
Unscrew the screws [B] and remove the guide [C].
Crankcase Assembly
NOTICE
Right and left crankcase halves are machined at the
factory in the assembled state, so if replaced, they
must be replaced as a set.
• Remove the old gasket from the mating surfaces of the

crankcase halves and clean them off with a high flash
-point solvent.
• Using compressed air, blow out the oil passages in the
crankcase halves.
WARNING
burns. Clean the engine parts in a well-ventilated
area, and take care that there is no spark or flame
anywhere near the working areas. Do not use
gasoline or low flash-point solvents to clean parts.
Crankcase
• Support the crankcase bearing boss with a suitable re-

tainer [A].
• Install the new bearing [B] with a press and the bearing
driver set [C].
NOTICE
Support the crankcase bearing boss when the bear-
ing is pressed, or the crankcase could be damaged.
Left Crankcase
•Press the new crankshaft bearing [A] until it bottoms out.
•Press the new shift drum needle bearing [B] so that the
bearing surface is flush with the crankcase surface.
• Press the new drive shaft bearing [A] so that the sealed
side [B] faces outside of the engine.
• Press the new output shaft bearing [C] so that the stepped
side [D] faces inside of the engine.
•○Install the left crankcase bearing retainers.

The left crankcase bearing retainers are smaller than right
ones.
• Apply a non-permanent locking agent to the crankcase
bearing retainer screws [A].
• Tighten:
Torque - Crankcase Bearing Retainer Screws: 15 N·m (1.5
kgf·m, 11 ft·lb)
• Press the new release shaft needle bearing (lower) [A] so

that the marked side faces upward and the distance from
the engine surface to the bearing end is 10 ~ 10.5 mm
(0.394 ~ 0.413 in.) [B].
•Press the new release shaft needle bearing (upper) [C]
so that the bearing surface is flush with the crankcase
surface [D] and the marked side faces upward.
•Press the new release shaft oil seal [E] so that the oil seal
surface is flush with the crankcase surface [F].
○Turn the flat side of the oil seal to upside.
• Apply grease to the oil seal lip.
Crankcase
• Press the new output shaft oil seal [A] so that the oil seal
surface is flush with the crankcase surface.
○Turn the metal side to outside of the engine.
• Press the new shift shaft oil seal [B] so that the oil seal
surface is flush with the crankcase surface.
• Install the reed valve [A] and guide [B].

• Tighten:
Torque - Reed Valve Screws [C]: 7.0 N·m (0.71 kgf·m, 62
in·lb)
Right Crankcase
•Press the new crankshaft bearing [A] and new drive shaft
bearing [B] until they bottom out.
Crankcase
• Press the new shift drum ball bearing [A] and new output
shaft bearing [B] so that the sealed side [C] faces outside
of the engine.
•○Install the right crankcase bearing retainers.

The right crankcase bearing retainers are larger than left
ones.
• Apply a non-permanent locking agent to the crankcase
bearing retainer screws [A].
• Tighten:
Torque - Crankcase Bearing Retainer Screws: 15 N·m (1.5
kgf·m, 11 ft·lb)
• Tighten:
Torque - Piston Oil Nozzle [A]: 2.9 N·m (0.30 kgf·m, 26 in·lb)
• Press the new crankshaft oil seal [A] so that the flat side
[B] faces inside of the engine.
○Press the oil seal from the outside (clutch cover side) so
that the oil seal end is flush with the crankcase surface
[C].
Crankcase
• Install:
Crankshaft (see Crankshaft Installation)
Transmission Shafts (see Transmission Shaft Installa-
tion)
• Install the oil screen (feed) [A] so that the shorter pipe side
faces upward.
• Position the connecting rod in BDC.
• Install the crankshaft jig [B] between the crankshaft fly-
wheels.
• Check to see that the dowel pins [C] are in place in the
mating surfaces of the crankcase halves.

that may be on the liquid gasket coating area. Dry them
with a clean cloth.
• Apply liquid gasket to the mating surface [A] of the left
crankcase half.
Sealant - Liquid Gasket, TB1216: 92104-1063
NOTE
○Especially, apply liquid gasket so that it shall be filled up
on the groove.
○Make the application finish within 20 minutes when the
liquid gasket to the mating surface of the left crankcase
half is applied.
○Moreover fit the case and tighten the case bolts just
after finishing the application of the liquid gasket.
• Assemble the crankcase halves evenly, while maintaining

the mating surfaces of them constantly parallel.
NOTE
○Press the crankcase rear portion [A], and tap the area
around the crankshaft with a plastic hammer [B].
○Constantly check the alignment of the crankcase
halves, and the position of the transmission shafts and
shift drum.
• Remove the crankshaft jig [C].

• Tighten the crankcase bolts, starting with the around of
the crankshaft, then outward.
○Tighten the [12] bolt together with the clamp.
Torque - Crankcase Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
NOTE
○After tightening the crankcase bolts, wipe up the liquid
gasket seeping out around the mating surface, espe-
cially around the area.
• Make sure that the crankshaft, drive shaft, and output

shaft, rotate smoothly (in the neutral position).
If the crankshaft will not turn, probably the crankshaft is
not centered; tap the mount portion of the engine with a
plastic hammer to reposition it. If it does not free up, split
the crankcase again and find the cause.
Crankcase
• Install the gear positioning lever and shift drum cam (see
External Shift Mechanism Installation).
• Check to see that gears shift smoothly from 1st to 5th
gear, and 5th to 1st while spinning the output shaft.
• Set the shift drum in the neutral position.
• Replace the O-rings [A] on the output shaft with new ones.
• Install the O-rings
Apply grease to the O-rings.
• O-ring. on the output shaft while expanding the
• Insert the collar [B] with the groove [C] faces inside.
Crankshaft
Crankshaft Removal
• Split the crankcase (see Crankcase Disassembly).
• Remove the transmission shafts and shift drum (see
Transmission Shaft Removal).
• Using a press, remove the crankshaft [A] from the right
crankcase.
If the bearing stay on the crankshaft when splitting the

crankcase, or removing the crankshaft from the right
crankcase, remove the bearings from the crankshaft with
a bearing puller [A].
Special Tool - Bearing Puller: 57001-135
Crankshaft Installation
• Apply engine oil to the outer side of the crankshaft bearing
and use the bearing driver set [A] and a press to drive the
bearing to the bottom of the crankcase [B]. While driving
the bearing in, make sure to use a holder to support the
boss area.
• Insert the crankshaft jig [A] between the crankshaft fly-

wheels to protect flywheel alignment, and press the crank-
shaft into the right crankcase.
○When pressing, position the jig in the crankcase opening
so the jig does not hit the crankcase.
• Apply engine oil to the connecting rod big end bearing.
Crankshaft Disassembly
Since the assembly of the crankshaft demands exacting
tolerances, the disassembly and reassembly of the crank-
shaft can only be done by a shop having the necessary tools
and equipment.
If it should be necessary to disassemble the crankshaft,
use a press to remove the crankpin.
Crankshaft Assembly
Since the assembly of the crankshaft demands exacting
tolerances, the disassembly and reassembly of the crank-
shaft can only be done by a shop having the necessary tools
and equipment.
Crankshaft
• Carefully align the oil passage hole in the right flywheel

[A] with the one in the crankpin [B] at rebuilding of the
crankshaft.
• Reassemble the crankshaft according to the standard tol-

erances in Specifications.
○Connecting rod bend, twist (see Connecting Rod Bend
Inspection, Connecting Rod Twist Inspection)
○Connecting rod big end radial clearance (see Crankshaft
Inspection)
○Cold-fitting tolerance between crankpin and flywheels
0.4 ∼ 0.8 mm (0.02 ∼ 0.03 in.) [A]
57.25 mm (2.254 in.) [B]
○ clearance between the connecting rod big end and
Side
one of flywheels (see Crankshaft Inspection)
○Crankshaft runout (see Crankshaft Inspection)
Crankshaft Inspection
Connecting Rod Big End Radial Clearance Inspection
•Set the crankshaft on V blocks, and place a dial gauge [A]
against the connecting rod big end.
•Push [B] the connecting rod first towards the gauge and
then in the opposite direction. The difference between
two gauge readings is the radial clearance.
Connecting Rod Big End Radial Clearance
Standard: 0.002 ∼ 0.014 mm (0.00008 ∼ 0.00055 in.)
If the radial clearance exceeds the service limit, crank-
shaft should be either replaced or disassembled and
crankpin, needle bearing, and connecting rod big end
should be examined for wear.
Connecting Rod Big End Side Clearance Inspection
•Refer to the Crankshaft Inspection in the Periodic Main-
tenance chapter.
Crankshaft Runout Inspection
•Set the crankshaft in a flywheel alignment jig or on V
blocks, and place a dial gauge and turn the crankshaft
slowly. The maximum difference in gauge reading is the
crankshaft runout.
8 mm (0.3 in.) [A]
Crankshaft Runout
If the runout at either point exceeds the service limit, re-
place the crankshaft assembly with a new one or align the
crankshaft so that the runout falls within the service limit.
Crankshaft
• First correct the horizontal misalignment by striking the

projecting crank half [A] with a plastic, soft lead, or brass
hammer.
• Recheck the runout with a dial gauge and repeat the
process until the runout falls within the service limit.
• Next, correct the vertical misalignment by either driving a

wedge [A] in between the crank halves or by squeezing
them in a vise, depending on the nature of the misalign-
ment.
NOTICE
Do not hammer the crank half at the point [B].
If flywheel misalignment cannot be corrected by the above
method, replace the crankpin or the crankshaft itself.
Connecting Rod Big End Seizure Inspection

In case of serious seizure with damaged flywheels, the
crankshaft must be replaced.
In case of less serious damage, disassemble the crank-
shaft and replace the crankpin, needle bearing, and con-
necting rod.
Crankshaft
Connecting Rod Bend Inspection
• Remove the connecting rod.
• Select an arbor [A] of the same diameter as the connect-
ing rod big end, and insert the arbor through the connect-
ing rod big end.
• Select an arbor [B] of the same diameter as the piston
pin and more than 105 mm (4.13 in.) long, and insert the
arbor through the connecting rod small end.
• On a surface plate, set the big-end arbor on a V block [C].
• With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If connecting rod bend exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Bend
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist Inspection

• With the big-end arbor [A] still on the V block [B], hold the
connecting rod horizontally and measure the amount that
the arbor [C] varies from being parallel with the surface
plate over a 100 mm (3.94 in.) length of the arbor to de-
termine the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the con-
necting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Transmission
Transmission Shaft Removal
• Split the crankcase (see Crankcase Disassembly).
• Pull out the shift rods [A], and remove the shift forks [B].
• Pull out the
Remove the shift drum [C].
• drive shaft [D] and output shaft [E] together.
Transmission Shaft Installation

• Apply engine oil to the following parts:
Transmission Shafts
Transmission Gears
Ball Bearings
Shift Drum
Shift Forks
• Install the drive shaft [A] and output shaft [B] in the right
crankcase with their gears meshed.
• Install the shift drum [A].

• grooves.output shaft shift forks [B] into the proper gear
Fit the
○Upturn the “057” mark of shift forks.

• Insert the shift rod [C] temporary.
• grooves.shift fork guide pin into the proper shift drum
Fit the
• Install the shift rod securely.

•○Upturn drive
Fit the shaft shift fork [D] into the proper position.
the “056” mark of shift fork.
• Install the shift rod [E] securely.
• Assembly
Check that each shaft moves smoothly.
• the crankcase (see Crankcase Assembly).
Transmission Shaft Disassembly
• Remove the transmission shafts (see Transmission Shaft
Removal).
• Remove the circlips, washers, then gears.
NOTE
○Do not reuse the removed circlips.
Transmission
Transmission Shaft Assembly
• Apply engine oil liberally to the transmission shaft, gears
and bearings.
•○Replace any circlips that were removed with new ones.
Always install the circlips [A] so that the opening [B] is
aligned with a spline groove [C], and install toothed wash-
ers. To install a circlip without damage, first fit the circlip
onto the shaft expanding it just enough to install it, and
then use a suitable gear to push the circlip into place.
• The drive shaft gears can be identified by size; the small-

est diameter gear is 1st gear, and the largest is 5th. Be
sure that all parts are put back in the correct sequence,
facing the proper direction, and that all circlips and washer
are properly in place.
○When install the bushing (for 4th) [A] to the drive shaft,
align the oil passage holes [B] each other.
• The output shaft gears can be identified by size; the

largest diameter gear is 1st gear, and the smallest is
5th. Be sure that all parts are put back in the correct
sequence, facing the proper direction, and that the circlip
is properly in place.
○Install the collar [A] with the flange [B] facing toward the
4th gear [C] side.
2nd Gear [D]
Transmission
KX250ZD
1. Circlip (Small) 11. Ball Bearing (Right Crankcase)

2. Toothed Washer 12. Output Shaft
3. Circlip (Large) 13. Ball Bearing (Left Crankcase)
4. Ball Bearing (Left Crankcase, One 14. Collar
side sealed) 15. 2nd Gear (28T)
5. 2nd Gear (16T) 16. 4th Gear (21T)
6. Bushing 17. 3rd Gear (26T)
7. 4th Gear (17T) 18. 5th Gear (23T)
8. 3rd Gear (18T) 19. 1st Gear (30T)
9. 5th Gear (22T) 20. Ball Bearing (Right Crankcase, One side sealed)
10. Drive Shaft (1st Gear, 14T)
Transmission
KX250ZE ∼
1. Circlip (Small) 11. Ball Bearing (Right Crankcase)

2. Toothed Washer 12. Output Shaft
3. Circlip (Large) 13. Ball Bearing (Left Crankcase)
4. Ball Bearing (Left Crankcase, One 14. Collar
side sealed) 15. 2nd Gear (28T)
5. 2nd Gear (16T) 16. 4th Gear (21T)
6. Bushing 17. 3rd Gear (26T)
7. 4th Gear (17T) 18. 5th Gear (23T)
8. 3rd Gear (18T) 19. 1st Gear (30T)
9. 5th Gear (22T) 20. Ball Bearing (Right Crankcase, One side sealed)
10. Drive Shaft (1st Gear, 14T)
• Check that each gear spins or slides freely on the trans-
mission shaft without binding after assembly.
Shift Fork Bending Inspection
• Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
Transmission
Shift Fork/Gear Groove Wear Inspection
• Measure the thickness [A] of the shift fork ears, and mea-
sure the width [B] of the gear grooves (with which the fork
engages).
Shift Fork Ear Thickness
Standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)
Gear Groove Width

Standard: 5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.)
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
If the gear groove is worn exceeding the service limit, the
gear must be replaced.
Shift Fork Guide Pin/Shift Drum Groove Wear
Inspection
• Measure the diameter [A] of each shift fork guide pin, and
measure the width [B] of each shift drum groove.
Shift Fork Guide Pin Diameter
Standard: 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Shift Drum Groove Width

Standard: 6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
If any shift drum groove is worn exceeding the service
limit, the drum must be replaced.
Gear Damage Inspection
• Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
• Visually inspect the gear teeth [C] on the transmission
gears.
Replace lightly damaged gear teeth with an oilstone. The
gear must be replaced if the teeth are badly damaged.
When gear is repaired or replaced, the driving gear should
also be inspected and repaired or replaced if necessary.
Primary Gear
Primary Gear Removal
• Remove:
•Temporarily install the clutch housing [A], clutch hub [B],
toothed washer and clutch hub nut [C].
•Hold the primary gear [D] with the gear holder [E].
○Pull out the clutch housing a little so that the gear holder
can be fit.
Special Tool - Gear Holder, m2.0: 57001-1557
•○Remove the primary gear nut [F] and washer.
The primary gear nut is left-hand threads.
• Remove:
Clutch Housing
Primary Gear
Primary Gear Installation
• Apply grease to the oil seal lip [A].
• Install: the primary gear nut [B] with a new one.
Replace
• Primary Gear [C]
Washer [D]
Primary Gear Nut
○ the inner rim of washer to outside.
Turn
○The primary gear nut is left-hand threads.
• Temporarily install the clutch housing [A], clutch hub [B],

toothed washer and clutch hub nut [C].
•○Hold the primary gear [D] with the gear holder [E].
Pull out the clutch housing a little so that the gear holder
can be fit.
Special Tool - Gear Holder, m2.0: 57001-1557
• Tighten:
Torque - Primary Gear Nut [F]: 98 N·m (10.0 kgf·m, 72 ft·lb)
External Shift Mechanism
Shift Pedal Removal
• Remove:
Shift Pedal Bolt [A]
Shift Pedal [B]
Shift Pedal Installation

• Install the shift pedal so that the slit [A] on the pedal aligns
with the punch mark [B] on the shift shaft.
• Tighten:
Torque - Shift Pedal Bolt [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
External Shift Mechanism Removal

• Remove:
Shift Pedal (see Shift Pedal Removal)
• Pull out the shift shaft [A].
• Remove:
Washer [A]
Ratchet Plate Bolt [B]
Ratchet Plate Screw [C]
Ratchet Plate [D]
Shift Ratchet Assembly [E]
• Remove the shift drum cam bolt [A].

• Hold the gear positioning lever [B] with suitable tool, and
remove the shift drum cam [C].
• Remove:
Gear Positioning Lever Nut [D] and Washer [E]
• Remove:
Pin [A]
Gear Positioning Lever [B]
Collar [C]
Spring [D]
External Shift Mechanism Installation

• Install:
Pin [A]
Spring [B]
Collar [C]
Gear Positioning Lever [D]
Washer
• Tighten:
Torque - Gear Positioning Lever Nut: 8.8 N·m (0.90 kgf·m,
78 in·lb)
• Hold the gear positioning lever [A] with the suitable tool
[B], and install the shift drum cam [C].
○Fit the groove [D] on the pin [E].
• Apply a non-permanent locking agent to the shift drum
cam bolt.
• Tighten:
Torque - Shift Drum Cam Bolt: 24 N·m (2.4 kgf·m, 18 ft·lb)
• Align the roller of the gear positioning lever with the slot
of the shift drum cam.
• Fit the spring end [A] to the notch of the gear positioning
lever.
• Turn the input shaft to check that the shift changes
smoothly.
• Set up the shift ratchet assembly.

Ratchet [A]
Pawls [B]
Pins [C]
Springs [D]
• Install the shift ratchet assembly [A] and ratchet plate [B]
as a set.
• Apply a non-permanent locking agent to the ratchet plate
screw and bolt.
• Tighten:
Torque - Ratchet Plate Screw [C]: 15 N·m (1.5 kgf·m, 11 ft·lb)
Ratchet Plate Bolt [D]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
○Tighten the screw first.
• Install the collar [E].
• Apply
[B].
grease to the oil seal lips [A] and shift shaft splines
• Install the washer [A] on the shift shaft [B].

•○Take care shift
Insert the shaft.
not to damage the oil seal when inserting the
shift shaft.
External Shift Mechanism Inspection

• Remove
moval).
the shift shaft (see External Shift Mechanism Re-
• Check the shift shaft [A] for bending or damage to the

splines.
If the shaft is bent, straighten or replace it. If the splines
are damaged, replace the shift shaft.
• Check the return spring [B] for cracks or distortion.
If the spring is damaged in any way, replace it.
• Check the shift lever [C] for distortion.
If the shift lever is damaged in any way, replace the shift
shaft.
• Check the shift ratchet assembly for any damage.

If the ratchet [A], pawls [B], pins [C] or springs [D] are
damaged in any way, replace them.
• Visually inspect the shift drum cam [A].

If it is badly worn or if it shows any damage, replace it.
• Check the gear positioning lever [A] and its spring [B] for
breaks or distortion.
If the lever or spring is damaged in any way, replace them.
Kickstarter
Kick Pedal Removal
• Remove:
Kick Pedal Bolt [A] and Washer
Kick Pedal Assy [B]
Kick Pedal Installation

•○Install the kick pedal assy.
Put the pedal end [A] near the cylinder head cover mating
surface [B].
the kick pedal bolt.
• Install the washer and tighten the kick pedal bolt.
Torque - Kick Pedal Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
Kick Pedal Disassembly

• Remove the kick pedal assy (see Kick Pedal Removal).
• Remove:
Plug Screw [A]
Spring [B]
Steel Ball [C]
Detent Screw [D]
Boss [E]
Oil Seal [F]
Kick Pedal Assembly

• Replace the oil seal [A] and plug screw [B] with a new one.
• sliding portiontoofthe
Apply grease steel ball, oil seal lip, spring, and the
the pedal.
• Install:
Oil Seal
Boss [C]
Detent Screw [D]
Steel Ball [E]
Spring [F]
Plug Screw
• Tighten the detent screw and plug screw.
• After tightening the plug screw, stake it with a punch.
Kickstarter
Kick Shaft Removal
• Remove:
Kickstarter Idle Gear [A]
• Pull the spring end [B] out of the hole.
• Turn the kick shaft counterclockwise [C] and pull out the
kickstarter assembly [D].
• Remove the bolt [A], and take off the ratchet guide [B].
Kick Shaft Installation

the kick ratchet guide bolt.
• Install the ratchet guide [A], and tighten the bolt.
Torque - Kick Ratchet Guide Bolt [B]: 8.8 N·m (0.90 kgf·m,
78 in·lb)
• Apply
[C].
molybdenum disulfide grease to the kick shaft end
•○Insert the kick shaft assembly into the crankcase.

Securely engage the stopper portion [D] of the ratchet
gear with the guide.
• Insert the spring end [E] into the hole [F].
• Apply molybdenum disulfide oil solution to the idle shaft.
Kick Shaft Assembly Disassembly/Assembly
• The kick shaft assembly consists of the following parts.
Circlips [A]
Washer ( 27.5 × 18.3) [B]
Spring [C]
Ratchet Gear [D]
Washer ( 22 × 18.3) [E]
Kick Gear [F]
Kick Shaft [G]
Kick Spring [H]
Spring Guide [I]
• Check the kick shaft assembly parts for damage. Any
damaged parts should be replaced with new ones.
Kickstarter
• Apply molybdenum disulfide grease [A] to the kick gear,

ratchet gear and kick shaft.
• Replace the circlips that were removed with new ones.
NOTE
○When assembling the ratchet gear [A] onto the kick
shaft [B], align the punch mark [C] on the ratchet gear
with the punch mark [D] on the kick shaft.
• Apply grease [A] to the inside of the spring guide [B].

• Fit the spring end [C] and hollow [D] on the spring guide.
Bearings/Oil Seals
Bearing Replacement
NOTICE
Do not remove the ball or needle bearings unless it
is necessary. Removal may damage them.
• Using a press or puller, remove the ball bearing and/or

needle bearings.
NOTE
○In the absence of the above mentioned tools, satisfac-
tory results may be obtained by heating the case to ap-
proximately 93°C (200°F) max, and tapping the bearing
in or out.
NOTICE
Do not heat the case with a torch. This will warp the
case. Soak the case in oil and heat the oil.
• Using a press and the bearing driver set [A], install the
new ball bearing until it stops at the bottom of its housing.
○The new needle bearings must be pressed into the
crankcase so that the end is flush with the end of the
hole.
Bearing Wear Inspection

NOTICE
Do not remove the bearings for inspection. Re-
moval may damage them.
•○Inspect the ball bearings.

Since the ball bearings are made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement.
○Clean each bearing in a high flash-point solvent, dry it (do
not spin the bearing while it is dry), and oil it with engine
oil.
○Spin [A] the bearing by hand to check its condition.

If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
Bearings/Oil Seals
•○Inspect the needle bearings.

The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of a needle bear-
ing, replace it.
Oil Seal Inspection
• Inspect the oil seals.
Replace the oil seal if the lips are deformed, discolored
(indicating that the rubber has deteriorated), hardened or
otherwise damaged.
WHEELS/TIRES 10-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 10-2
Specifications ......................................................................................................................... 10-4
Special Tools .......................................................................................................................... 10-5
Wheels (Rims) ........................................................................................................................ 10-6
Front Wheel Removal ....................................................................................................... 10-6
Front Wheel Installation .................................................................................................... 10-6
Rear Wheel Removal........................................................................................................ 10-7
Rear Wheel Installation..................................................................................................... 10-8
Wheels Inspection............................................................................................................. 10-10
Spoke Tightness Inspection .............................................................................................. 10-10
Rim Runout Inspection...................................................................................................... 10-10
Rim Installation Position.................................................................................................... 10-10
Axle Inspection.................................................................................................................. 10-10
Tires........................................................................................................................................ 10-11
Air Pressure Inspection/Adjustment.................................................................................. 10-11
Tire Removal..................................................................................................................... 10-11
Tire Installation.................................................................................................................. 10-12
Hub Bearing............................................................................................................................ 10-14
Front Hub Bearing Removal ............................................................................................. 10-14
Rear Hub Bearing Removal .............................................................................................. 10-14 10
Hub Bearing Installation.................................................................................................... 10-15
Hub Bearing Inspection..................................................................................................... 10-16
Hub Bearing Lubrication ................................................................................................... 10-16
10-2 WHEELS/TIRES
Exploded View
WHEELS/TIRES 10-3
Exploded View
Torque
N·m kgf·m ft·lb
Not less Not less Not less
1 Spoke Nipples
than 2.2 than 0.22 than 19 in·lb
2 Front Axle Nut 78 8.0 58
3 Front Axle Clamp Bolts 20 2.0 15 AL, S
4 Rear Axle Nut (KX250ZD ∼ ZE) 108 11.0 79.7
5 Rear Axle Nut (KX250ZF) 108 11.0 79.7 R
6. KX250ZD ∼ ZE
HG: Apply high-temperature grease.
WL: Apply soap and water solution or rubber lubricant.
10-4 WHEELS/TIRES
Specifications

Wheels (Rims)
Rim Size:
Front 21 × 1.60 – – –
Rear 19 × 1.85 – – –
Rim Runout:
Axial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm (0.08 in.)
Radial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm (0.08 in.)
Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.001 in.) or less TIR 0.2 mm (0.008 in.)
Tires
Air Pressure (when cold):
Front/Rear 100 kPa (1.00 kgf/cm², 14 psi) – – –
Standard Tire:
Front:
Size 80/100-21 51M – – –
Type MX51FA, Tube – – –
Rear:
Size 100/90-19 57M – – –
Type MX51, Tube – – –
WHEELS/TIRES 10-5
Special Tools
Inside Circlip Pliers: Bearing Remover Head, 20 × 22:
57001-143 57001-1293
Rim Protector: Bearing Remover Head, 25 × 28:

57001-1063 57001-1346
Bearing Driver Set: Bearing Remover Shaft, 13:

57001-1129 57001-1377

57001-1238 57001-1608
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Remove the axle nut [A].
• Loosen the axle clamp bolts [B] on both sides.
• Raise the front wheel off the ground with jack.
• Pull out the axle and remove the wheel.
• Remove the collars [A] with caps [B] on both sides.

NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground.
•○Insert a wood wedge between the brake pads.

This prevents them from being moved out of their proper
position, should the brake lever be squeezed accidentally.
Front Wheel Installation
• Apply high-temperature grease to the grease seal lips.
•○Install the caps and collars to the hub on both sides.
Fit the projection [A] and groove [B].
• Install the front wheel.
• Insert the axle [A] from right side.

• Tighten:the front axle clamp bolts (right) [B] temporarily.
Screw
•
Torque - Front Axle Nut [C]: 78 N·m (8.0 kgf·m, 58 ft·lb)
Front Axle Clamp Bolts (Left) [D]: 20 N·m (2.0
kgf·m, 15 ft·lb)
NOTE
• Loosen the front axle clamp bolts (right).

• Remove the jack.
WHEELS/TIRES 10-7
Wheels (Rims)
• Pump the front fork up and down [A] 4 or 5 times to align

both fork positions.
NOTE
○Put a block [B] in front of the wheel to stop moving.
○Do not apply the front brake.
• Tighten:
Torque - Front Axle Clamp Bolts (Right): 20 N·m (2.0 kgf·m,
15 ft·lb)
NOTE
• Check the front brake for good braking power and no

brake drag.
WARNING
Rear Wheel Removal

• Using the jack under the frame so that the rear wheel is
raised off the ground.
• Squeeze the front brake lever, and hold it with a band [A]
to prevent the motorcycle from running forward.
WARNING
Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the rear wheel.
NOTICE
Be sure to hold the front brake when removing the
rear wheel, or the motorcycle may fall over. The rear
wheel or the motorcycle could be damaged.
10-8 WHEELS/TIRES
Wheels (Rims)
• Remove the cotter pin [A] (KX250ZD ∼ ZE).

• Pull out the axle
Remove the rear axle nut [B] and the washer [C].
• both sides. [D], and remove the chain adjuster [E] on
[F] KX250ZD ∼ ZE
[G] KX250ZF
• Disengage the drive chain from the rear sprocket.
• Remove the rear wheel.
• Remove the collars [A] with caps [B] on both sides.

NOTICE
Place blocks under the wheel so the disc does not
touch the ground.
•○Insert a wood wedge between the brake pads.

This prevents them from being moved out of their proper
position, should the brake pedal be squeezed acciden-
tally.
Rear Wheel Installation
• Fit
[B].
the groove [A] of the caliper holder and swingarm rib
WHEELS/TIRES 10-9
Wheels (Rims)
• Apply high-temperature grease to the grease seal lips.

•○Fit the the
Install caps and collars to the hub on both sides.
projection [A] and groove [B].
• Install the rear wheel.

• Install thethechain
Engage drive chain with the rear sprocket.
• Adjuster [A] (Leftadjusters
Side)
on the swingarm.
Flat Adjuster [B] (Right Side)

• For KX250ZF, inspect the rear axle nut (see the the Rear
Axle Nut Inspection (KX250ZF) in the Periodic Mainte-
nance chapter).
• Insert the axle from left side, and tighten the axle nut.
Torque - Rear Axle Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb)
KX250ZD ∼ ZE
•Insert a new cotter pin [A].
NOTE
○When 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 [B] up to next alignment.
○It should be within 30 degrees.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut.

WARNING
A loose axle nut can lead to an accident resulting in
serious injury or death. Tighten the axle nut to the
proper torque and install a new cotter pin.
• Adjust the drive chain slack (see Drive Chain Slack In-
spection in the Periodic Maintenance chapter).
• Check the rear brake for good braking power and no
brake drag.
WARNING
brake pedal before the brake pads contact the disc,
brake pedal is obtained by pumping the pedal until
10-10 WHEELS/TIRES
Wheels (Rims)
Wheels Inspection
• Refer to the Wheel Bearing Inspection in the Periodic
Spoke Tightness Inspection
• Refer to the Spoke Tightness Inspection in the Periodic
Rim Runout Inspection
• Refer to the Rim Runout Inspection in the Periodic Main-
tenance chapter.
Rim Installation Position
•○When installing the rim, set the rim following position.
The distance [A] from the brake disc seating surface [B]
of the front hub [C] to left end of the front rim [D] should
be as follows.
View from Front [E]
Distance: 26.8 ±0.5 mm (1.06 ±0.020 in.)
○The distance [A] from the brake disc seating surface [B]
of the rear hub [C] to right end of the rear rim [D] should
be as follows.
View from Rear [E]
Distance: 32.8 ±0.5 mm (1.29 ±0.020 in.)
• Check the rim runout (see Rim Runout Inspection in the

Periodic Maintenance chapter).
Axle Inspection
• Visually inspect the front and rear axle for damages.
If the axle is damaged or bent, replace it.
• Place the axle on V blocks that are 100 mm (3.94 in.)
[A] apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks.
•Turn [C] the axle to measure the runout.
○The difference between the highest and lowest dial read-
ings is the amount of runout.
Axle Runout/100 mm (3.94 in.)
If the runout exceeds the service limit, replace the axle.
WHEELS/TIRES 10-11
Tires
Air Pressure Inspection/Adjustment
• Refer to the Air Pressure Inspection/Adjustment in the Pe-
Tire Removal
• Remove the wheel (see Front/Rear Wheel Removal).
NOTICE
Do not lay the wheel directly on the ground with
the disc facing down. This can damage or warp the
disc. Place blocks under the wheel so that the disc
does not touch the ground.
• To maintain wheel balance, mark [A] the air valve position

on the tire with chalk so that the tire can be reinstalled in
the same position.
Align [B]
• Remove the air valve cap [C].
• Take out the valve core [A] to let out the air.
• Remove the air valve nut.
• Loosen the bead protector nut [A].

• a soap andthewater
Lubricate tire beads and rim flanges on both sides with
solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
NOTICE
Never lubricate with engine oil or petroleum distil-
lates because they will deteriorate the tire.
• Break the beads away from both sides of the rim with a
suitable bead breaker.
10-12 WHEELS/TIRES
Tires
• Lubricate the suitable tire irons [A] and rim protectors [B]
with soap and water solution or rubber lubricant.
Special Tool - Rim Protector: 57001-1063
• Step on the side of the tire opposite air valve, and pry the
tire off the rim with the tire irons protecting the rim with rim
protectors.
NOTICE
Take care not to insert the tire irons so deeply that
the tube gets damaged.
• Remove the tube and bead protector when one side of

the tire is pried off.
• Pry the other side of the tire off the rim.
Tire Installation
NOTE
○The tires should be installed so that the ID serial NO.
[A] faces to left side.
• Inspect the rim and tire before installing the tire, and re-
place them if necessary.
• Install the tube band onto the rim.
• Apply a soap and water solution or rubber lubricant to both
the tire bead and rim flange.
• Position the tire on the rim so that the air valve [A] is at
the tire balance mark [B] (the chalk mark made during
removal).
○The new tire is no marked.
• Insert
loosely.
the valve stem into the rim, and screw the nut on
• Fit the rim protectors and use suitable tire irons to install
the tire bead.
Special Tool - Rim Protector: 57001-1063
NOTICE
To prevent rim damage, be sure to place the rim
protectors at any place the tire irons are applied.
• Install
valve.
the tire on the rim from the opposite side of the air
○Fit the rim protectors and insert the tire irons so deeply
that the tube is not damaged.
• Install the bead protector onto the rim.
• Similarly, slip the tire bead over the rim on the other side.
• Check that the tube is not pinched between the tire and
rim.
WHEELS/TIRES 10-13
Tires
• Tighten the bead protector nut [A], air valve nut [B] and
air valve cap [C].
• Adjust the tire air pressure to the specified pressure (see
Air Pressure Inspection/Adjustment in the Periodic Main-
tenance chapter).
10-14 WHEELS/TIRES
Hub Bearing
Front Hub Bearing Removal
• Remove:
Front Wheel (see Front Wheel Removal)
Grease Seals [A]
• Use the bearing remover to remove the hub bearings [A].

NOTICE
Place wooden blocks under the wheel so that the
disc does not touch the ground.
Special Tools - Bearing Remover Head, 20 × 22 [B]:

57001-1293
Bearing Remover Shaft, 13 [C]: 57001
-1377
• Remove the collar [D].
Rear Hub Bearing Removal
• Remove:
Rear Wheel (see Rear Wheel Removal)
Grease Seals [A]
Circlip [B]
• Use
[A].
the bearing remover to remove the right hub bearing
NOTICE
Place wooden blocks under the wheel so that the
disc does not touch the ground.
Special Tools - Bearing Remover Head, 25 × 28 [B]:

57001-1346
Bearing Remover Shaft, 13 [C]: 57001
-1377
• Remove the collar [D].
WHEELS/TIRES 10-15
Hub Bearing
• Using a suitable bar [A], tap the around of the bearing

inner race evenly to remove the bearings [B].
Hub Bearing Installation

• Before installing the hub bearings, blow any dirt or foreign
particles out of the hub with compressed air to prevent
contamination of the bearings.
• Replace the bearings with new ones.
NOTE
○Install the bearings so that the marked side or sealed
side faces out.
•○Install the front hub bearings in the following sequence.

Press in the left side bearing [A] until it is bottomed.
○Insert the collar [B] in the front hub [C].
○Press in the right side bearing [D] until it is bottomed.
•○Install the rear hub bearings in the following sequence.
Press in the right side bearing until it is bottomed.
○Insert the collar in the rear hub.
○Press in the left side bearings until it is bottomed.
○Replace the circlip with a new one and install a new circlip.
• Replace the grease seal [A] with a new one.

• [B] with the end
Press in the grease seal so that the seal surface is flush
of the hole.
• Apply high-temperature grease to the grease seal lip.
Special Tool - Bearing Driver Set [C]: 57001-1129
10-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Inspection
Since the hub bearings are made to extremely close tol-
erances, the clearance cannot normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bear-
ings are removed, they will need to be replaced with
new ones.
• Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding.
If bearing play roughness, or binding is found, replace the
bearing.
• Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication
NOTE
○Since the hub bearings are packed with grease and
sealed, lubrication is not required.
FINAL DRIVE 11-1
Final Drive
Table of Contents
Exploded View........................................................................................................................ 11-2
Specifications ......................................................................................................................... 11-4
Special Tool ............................................................................................................................ 11-5
Drive Chain............................................................................................................................. 11-6
Drive Chain Slack Inspection ............................................................................................ 11-6
Drive Chain Slack Adjustment .......................................................................................... 11-6
Wheel Alignment Inspection ............................................................................................. 11-6
Wheel Alignment Adjustment............................................................................................ 11-6
Drive Chain Wear Inspection ............................................................................................ 11-6
Drive Chain Lubrication..................................................................................................... 11-6
Drive Chain Removal ........................................................................................................ 11-6
Drive Chain Installation ..................................................................................................... 11-7
Sprockets................................................................................................................................ 11-8
Engine Sprocket Removal ................................................................................................ 11-8
Engine Sprocket Installation ............................................................................................ 11-8
Rear Sprocket Removal.................................................................................................... 11-9
Rear Sprocket Installation................................................................................................. 11-9
Sprocket Wear Inspection................................................................................................. 11-9
Rear Sprocket Warp (Runout) Inspection ......................................................................... 11-9
11
11-2 FINAL DRIVE
Exploded View
FINAL DRIVE 11-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Rear Sprocket Nuts 34 3.5 25 R
2 Engine Sprocket Nut (KX250ZE ∼) 78 8.0 57
3. KX250ZD
HO: Apply heavy oil.
11-4 FINAL DRIVE
Specifications

Drive Chain
Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – –
Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)
Standard Chain:
Make DAIDO – – –
Type DID 520DMA4 – – –
Link 114 links – – –
Sprocket
Rear Sprocket Warp TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm (0.020 in.)
FINAL DRIVE 11-5
Special Tool
Outside Circlip Pliers:
57001-144
11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
• Refer to the Drive Chain Slack Inspection in the Periodic
Drive Chain Slack Adjustment
• Refer to the Drive Chain Slack Adjustment in the Periodic
Wheel Alignment Inspection
• Check that the notch [A] of the chain adjuster [B] aligns
with the same swingarm mark [C] as the other side one.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.
Wheel Alignment Adjustment

• This procedure is the same as Drive Chain Slack Adjust-
ment (see Drive Chain Slack Adjustment in the Periodic
Drive Chain Wear Inspection
• Refer to the Drive Chain Wear Inspection in the Periodic
Drive Chain Lubrication
• Refer to the Drive Chain Lubrication in the Periodic Main-
tenance chapter.
Drive Chain Removal
• Remove the engine sprocket cover (see Engine Sprocket
Removal).
• Remove the clip [A] from the master link with pliers.
• Remove:
Link Plate [A]
Master Link [B]
Drive Chain [C]
FINAL DRIVE 11-7
Drive Chain
Drive Chain Installation
•○Fit the drive chain onto the sprockets.
Place the drive chain ends on the rear sprocket.
• Install the master link [A] from the wheel side.
• Install the link plate [A] so that the mark faces out.
• pointedthein the
Install clip [B] so that the closed end [C] of the “U”
direction of chain rotation [D].
• justment in the Periodic
Adjust the drive chain slack (see Drive Chain Slack Ad-
• Installation).
Install the engine sprocket cover (see Engine Sprocket
11-8 FINAL DRIVE
Sprockets
Engine Sprocket Removal
• Remove:
Engine Sprocket Cover Bolts [A]
Engine Sprocket Cover [B]
Drive Chain Guide [C]
KX250ZD
•Remove:
Circlip [A]
• Remove the engine sprocket [B] from the drive chain [C].
KX250ZE ∼
•Flatten the bended sprocket washer [A].
•Remove:
Engine Sprocket Nut [B]
Sprocket Washer
•Remove the engine sprocket [C] from the drive chain [D].
Engine Sprocket Installation

KX250ZD
•Engage the drive chain [A] to the engine sprocket [B] and
install the engine sprocket on the output shaft.
•Replace the circlip with a new one.
•Install the new circlip on the groove of the output shaft.
• Run the gear position switch lead properly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
• Install the drive chain guide and engine sprocket cover,
and then tighten the bolts.
○Do not pinch the gear position switch lead.
FINAL DRIVE 11-9
Sprockets
KX250ZE ∼
•Engage the drive chain [A] to the engine sprocket [B] and
install the engine sprocket on the output shaft.
•Replace the sprocket washer with a new one.
•Install the sprocket washer and sprocket nut.
•Tighten:
Torque - Engine Sprocket Nut: 78 N·m (8.0 kgf·m, 57 ft·lb)
• Bend the one side of the sprocket washer on the nut.
• Run the gear position switch lead properly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).
• Install the drive chain guide and engine sprocket cover,
and then tighten the bolts.
○Do not pinch the gear position switch lead.
Rear Sprocket Removal
• Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).
NOTICE
Place blocks under the wheel so that the disc does
not touch the ground.
• Remove:
Rear Sprocket Bolts [A] and Nuts
Washers
Rear Sprocket [B]
Rear Sprocket Installation

• Replace the rear sprocket nuts with new ones.
• faces out. rear sprocket [A] so that the marked side [B]
Install the
• Install the rear sprocket bolts and washers.

• Tighten:
Torque - Rear Sprocket Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Sprocket Wear Inspection

• Refer to the Sprocket Wear Inspection in the Periodic
Rear Sprocket Warp (Runout) Inspection
• Refer to the Rear Sprocket Warp (Runout) Inspection in
BRAKES 12-1
Brakes
Table of Contents
Exploded View........................................................................................................................ 12-2
Specifications ......................................................................................................................... 12-6
Special Tools .......................................................................................................................... 12-7
Brake Lever, Brake Pedal....................................................................................................... 12-8
Brake Lever Play Adjustment............................................................................................ 12-8
Brake Pedal Position Adjustment...................................................................................... 12-8
Brake Pedal Removal ....................................................................................................... 12-8
Brake Pedal Installation .................................................................................................... 12-8
Brake Fluid ............................................................................................................................. 12-10
Brake Fluid Level Inspection............................................................................................. 12-10
Brake Fluid Change .......................................................................................................... 12-10
Brake Line Bleeding.......................................................................................................... 12-11
Caliper .................................................................................................................................... 12-13
Caliper Removal ............................................................................................................... 12-13
Caliper Installation ............................................................................................................ 12-14
Caliper Disassembly ......................................................................................................... 12-14
Fluid Seal Damage Inspection .......................................................................................... 12-15
Dust Seal Damage Inspection .......................................................................................... 12-15
Caliper Dust Boot and Friction Boot Damage Inspection.................................................. 12-15
Caliper Piston and Cylinder Damage Inspection .............................................................. 12-16
Caliper Holder Shaft Wear Inspection............................................................................... 12-16
Brake Pad............................................................................................................................... 12-17
Brake Pad Removal .......................................................................................................... 12-17
Brake Pad Installation ....................................................................................................... 12-17 12
Brake Pad Inspection........................................................................................................ 12-18
Master Cylinder ...................................................................................................................... 12-19
Front Master Cylinder Removal ........................................................................................ 12-19
Front Master Cylinder Installation ..................................................................................... 12-19
Rear Master Cylinder Removal......................................................................................... 12-20
Rear Master Cylinder Installation...................................................................................... 12-20
Front Master Cylinder Disassembly .................................................................................. 12-21
Rear Master Cylinder Disassembly................................................................................... 12-21
Master Cylinder Assembly ................................................................................................ 12-21
Master Cylinder Inspection (Visual Inspection)................................................................. 12-22
Brake Disc .............................................................................................................................. 12-23
Brake Disc Removal ......................................................................................................... 12-23
Brake Disc Installation ...................................................................................................... 12-23
Brake Disc Inspection ....................................................................................................... 12-23
Brake Hose............................................................................................................................. 12-24
Brake Hose Removal/Installation...................................................................................... 12-24
Brake Hose Inspection...................................................................................................... 12-24
12-2 BRAKES
Exploded View
BRAKES 12-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Brake Hose Banjo Bolts 25 2.5 18
2 Front Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
3 Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
4 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si
5 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
6 Front Brake Disc Mounting Bolts 9.8 1.0 87 in·lb L
7 Front Brake Pad Pin 17 1.7 13
8 Caliper Bleed Valve 7.8 0.80 69 in·lb
9 Front Caliper Mounting Bolts 25 2.5 18
10. KX250ZF
B: Apply brake fluid.
12-4 BRAKES
Exploded View
BRAKES 12-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Brake Hose Banjo Bolts 25 2.5 18
2 Rear Brake Reservoir Cap Bolts 1.5 0.15 13 in·lb
3 Rear Master Cylinder Mounting Bolts 9.8 1.0 87 in·lb
4 Rear Master Cylinder Push Rod Locknut 17 1.7 13
5 Brake Pedal Bolt 25 2.5 18 G, L
6 Rear Caliper Holder Shaft 27 2.8 20 Si
7 Rear Brake Pad Pin 17 1.7 13
8 Rear Brake Pad Pin Plug 2.4 0.24 21 in·lb
9 Caliper Bleed Valve 7.8 0.80 69 in·lb
10 Rear Brake Disc Mounting Bolts 23 2.3 17 L
11. KX250ZF
B: Apply brake fluid.
G: Apply grease.
12-6 BRAKES
Specifications

Brake Lever
Lever Free Play Adjustable (to suit rider) – – –
Brake Fluid
Grade:
Front DOT3 or DOT4 – – –
Rear DOT3 or DOT4 – – –
Brake Pads
Lining Thickness:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.)
Brake Discs
Thickness:
Front 2.85 ∼ 3.15 mm (0.112 ∼ 0.124 in.) 2.5 mm (0.10 in.)
Rear 3.85 ∼ 4.15 mm (0.152 ∼ 0.163 in.) 3.5 mm (0.14 in.)
Runout TIR 0.25 mm (0.010 in.) or less TIR 0.3 mm (0.01 in.)
BRAKES 12-7
Special Tools
57001-1238 57001-1608
12-8 BRAKES
Brake Lever, Brake Pedal
Brake Lever Play Adjustment
• Refer to the Brake Lever and Pedal Adjustment in the
Brake Pedal Position Adjustment
• Refer to the Brake Lever and Pedal Adjustment in the
Brake Pedal Removal
• Remove:
Cotter Pin [A]
Joint Pin [B]
Washer [C]
NOTE
○Pull off the joint pin while pressing down the brake
pedal.
• Remove:
Brake Pedal [C] and Washer
Brake Pedal Installation

• Install the return spring [A].
• Replace the O-rings [A] with new ones.

• Apply grease to the O-rings and shaft portion [B] of the
brake pedal bolt.
• Apply a non-permanent locking agent to the thread of the
brake pedal bolt.
•○Install the brake pedal [C].
Install the washer [D] inside the pedal.
• Tighten:
Torque - Brake Pedal Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
BRAKES 12-9
Brake Lever, Brake Pedal
• Replace the cotter pin with a new one.

• Bend the ends
Install the joint pin, washer and new cotter pin.
• Check the brake[A] pedal
of the cotter pin.
• Pedal Adjustment in the Periodic
position (see Brake Lever and
12-10 BRAKES
Brake Fluid
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been
left unsealed or that has been open for a long
time.
3. Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffec-
tive. It may also cause the rubber brake parts to
deteriorate.
4. Don’t leave the reservoir cap off for any length
of time to avoid moisture contamination of the
fluid.
5. Don’t change the fluid in the rain or when a
strong wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol
for cleaning of the brake parts. Do not use any
other fluid for cleaning these parts. Gasoline,
engine oil, or any other petroleum distillate will
cause deterioration of the rubber parts. Oil
spilled on any part will be difficult to wash off
completely and will eventually deteriorate the
rubber used in the disc brake.
7. When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets
on the pads or disc with a high flash-point sol-
vent. Do not use one which will leave an oily
residue. Replace the pads with new ones if they
cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up im-
mediately.
9. If any of the brake line fittings or the bleed valve
is opened at any time, the AIR MUST BE BLED
FROM THE BRAKE LINE.
Brake Fluid Level Inspection

• Refer to the Brake Fluid Level Inspection in the Periodic
Brake Fluid Change
• Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.
BRAKES 12-11
Brake Fluid
Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If the brake lever has a soft or "spongy" feel-
ing mushy when it is applied, there might be air in
the brake lines or the brake may be defective. Do
not operate the vehicle and service the brake sys-
tem immediately.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
• Level the brake fluid reservoir.

• Screws [A]
Remove:
Reservoir Cap [B]

Diaphragm
•Check that there is plenty of fluid in the reservoir.
•Slowly pump the brake lever several times until no air
bubbles rise up from the bottom of the reservoir.
○Bleed the air completely from the master cylinder by this
operation.
• Remove
caliper.
the rubber cap [A] from the bleed valve on the
• Attach a clear plastic hose [B] to the bleed valve on the

caliper, and run the other end of the hose into a container.
12-12 BRAKES
Brake Fluid
•○Bleed the brake line and caliper as follows:

Repeat this operation until no more air can be seen com-
ing out into the clear plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while holding
the brake applied.
3. Release the brake [C].
NOTE
○The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs almost out
any time during bleeding operation, the bleeding opera-
tion must be done over again from the beginning since
air will have entered the line.
○Tap the brake hose lightly from the caliper to the reser-
voir for easier bleeding.
• Remove the clear plastic hose.

• Tighten the bleed valve, and install the rubber cap.
• Check the fluid level (see Brake Fluid Level Inspection in

the Periodic Maintenance chapter).
• Install the diaphragm and reservoir cap.
• Tighten:
Torque - Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
• After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.
WARNING
BRAKES 12-13
Caliper
Caliper Removal
Front Brake
• Loosen the brake pad pin [A] before the caliper [B] re-
moval if the caliper is to be disassembled.
• Loosen the banjo bolt [C] so as not to spill brake fluid.
NOTE
○If the caliper is to be disassembled after removal and
compressed air is not available, disassemble the caliper
before brake hose removal (see Caliper Rubber Parts
Replacement in the Periodic Maintenance chapter).
• Remove:
Caliper Mounting Bolts [D]
Banjo Bolt
Caliper
NOTICE
Immediately wipe up any brake fluid that is spilled.
Rear Brake
•Remove:
Caliper Guard Bolts [A]
Caliper Guard [B]
Disc Guard Bolts [C]
Disc Guard [D]
• Remove the pad pin plug [A] and loosen the pad pin [B] if
the caliper [C] is to be disassembled.
• Loosen the banjo bolt [D] so as not to spill brake fluid.
NOTE
○If the caliper is to be disassembled after removal and
compressed air is not available, disassemble the caliper
before brake hose removal (see Caliper Rubber Parts
Replacement in the Periodic Maintenance chapter).
• Remove:
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Banjo Bolt
Caliper
NOTICE
Immediately wipe up any brake fluid that is spilled.
12-14 BRAKES
Caliper
Caliper Installation
• Install the brake pad if it was removed (see Brake Pad
Installation).
Front Brake
• Install the caliper and tighten the bolts.
Torque - Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Brake
•Install the rear wheel and caliper (see Rear Wheel Instal-
lation in the Wheels/Tires chapter).
•○Install the brake hose lower end.

Replace the washers [A] on each side of hose fitting [B]
with new ones.
• Tighten:
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Bleed the brake line (see Brake Line Bleeding).
• and nothe
Check brake for good braking power, no brake drag,
fluid leakage.
WARNING
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.
Caliper Disassembly
• Refer to the Caliper Rubber Parts Replacement in the Pe-
BRAKES 12-15
Caliper
Fluid Seal Damage Inspection
The fluid seal(s) [A] around the piston maintains the
proper pad/disc clearance. If this seal is not in good condi-
tion, pad wear will increase, and constant pad drag on the
disc will raise brake and brake fluid temperature.
• Replace the fluid seals under any of the following condi-
tions.
○Fluid leakage around the pad
○Brakes overheat
○There is a large difference in left and right pad wear.
○The seal is stuck to the piston.
If the fluid seal(s) is replaced, replace the dust seal(s) [B]
as well. Also, replace all seals every other time the pads
are changed.
Front Caliper [C]
Rear Caliper [D]
Dust Seal Damage Inspection

• Check that the dust seals are not cracked, worn, swollen,
or otherwise damaged.
If they show any damage, replace them.
Caliper Dust Boot and Friction Boot Damage
Inspection
• Check that the dust boot [A] and friction boot [B] are not
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
Front Caliper [C]
Rear Caliper [D]
12-16 BRAKES
Caliper
Caliper Piston and Cylinder Damage Inspection
• Visually inspect the piston(s) [A] and cylinder surfaces.
Replace the caliper if the cylinder and piston are badly
scores or rusty.
Front Caliper [B]
Rear Caliper [C]
Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder
shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
perature.
• Check to see that the caliper holder shafts are not badly
worn or stepped, and that the friction boots are not dam-
aged.
If the friction boot is damaged, replace the friction boot.
To replace the friction boot, remove the pads and caliper
bracket.
If the caliper holder shaft is damage, replace the caliper
assembly (front caliper), caliper bracket or holder shaft
(rear caliper).
Torque - Rear Caliper Holder Shaft: 27 N·m (2.8 kgf·m, 20
ft·lb)
Front Caliper [B]
Rear Caliper [C]
BRAKES 12-17
Brake Pad
Brake Pad Removal
Front Brake
• Remove the pad pin [A].
• Remove the piston side pad [B].
• Push the caliper holder toward the piston, and then re-
move another pad [C].
Rear Brake
•Remove:
Pad Pin Plug [A]
• Remove the pad pin [A].

• Push the caliper
Remove the piston side pad [B].
• move another padholder
[C].
toward the piston, and then re-
Brake Pad Installation

• Push
go.
the caliper piston(s) in by hand as far as they will
•○Install the piston side pad first, and then another pad.
Fit the pad end into the groove [A] of the anti-rattle spring
securely.
Front Brake [B]
Rear Brake [C]
12-18 BRAKES
Brake Pad
• Tighten the brake pad pin.

Torque - Brake Pad Pin: 17 N·m (1.7 kgf·m, 13 ft·lb)
Rear Brake Pad Pin Plug: 2.4 N·m (0.24 kgf·m, 21
in·lb)
• Check the brake for good braking power, no brake drag,
and no fluid leakage.
WARNING
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.
Brake Pad Inspection

• Refer to the Brake Pad Wear Inspection in the Periodic
BRAKES 12-19
Master Cylinder
NOTICE
Brake fluid quickly ruins painted or plastic sur-
faces; any spilled fluid should be completely
washed up immediately.
Front Master Cylinder Removal

• Remove the banjo bolt [A] to disconnect the brake hose
upper end [B] from the master cylinder [C].
○When removing the brake hose, temporarily secure the
loss to a minimum.
• Remove the clamp bolts [A], and take off the master cylin-
der [B] as an assembly with the brake lever.
Front Master Cylinder Installation

• Install the master cylinder [A].
176.95 mm (6.967 in.) [B]
Horizontal Line of Frame [C]
Handlebars [D]
Horizontal Line of Cap Surface [E]
12-20 BRAKES
Master Cylinder
• The master cylinder clamp must be installed with the ar-

row mark [A] upward.
• Tighten the upper clamp bolt [B] first, and then the lower
clamp bolt [C].
○There will be a gap at the lower mating surface of the
clamp after tightening.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90
kgf·m, 78 in·lb)
•○Install the brake hose.

with new ones.
• Tighten:
• and nothe
fluid leakage.
WARNING
Rear Master Cylinder Removal

• Remove:
Cotter Pin [A]
Joint Pin [B]
Washer [C]
NOTE
○Pull off the joint pin while pressing down the brake
pedal.
• Remove the master cylinder mounting bolts [D], and re-

move the master cylinder [E] backward.
•○Remove the brake hose banjo bolt [F].
When removing the brake hose, temporarily secure the
loss to a minimum.
Rear Master Cylinder Installation
•○Install the brake hose.
with new ones.
• Tighten:
• Install the rear master cylinder.
• Tighten:
Torque - Rear Master Cylinder Mounting Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
BRAKES 12-21
Master Cylinder

• Bend the ends
Install the joint pin, washer and new cotter pin.
• [A] of the cotter pin.
• Check the brake pedal position (see Brake Lever and

Pedal Adjustment in the Periodic Maintenance chapter).
• and nothe
fluid leakage.
WARNING
brake pedal before the brake pads contact the disc,
brake pedal is obtained by pumping the pedal until
Front Master Cylinder Disassembly

• Refer to the Brake Master Cylinder Rubber Parts Re-
placement in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
Master Cylinder Assembly
12-22 BRAKES
Master Cylinder
Master Cylinder Inspection (Visual Inspection)
• Disassemble the front and rear master cylinders.
• Check that there are no scratches, rust or pitting on the
inner wall of each master cylinder [A] and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
• Inspect the primary [C] and secondary [D] cups.
If a cup is worn, damaged, softened (rotted), or swollen,
the piston assembly should be replace to renew the cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cup.
• Check the dust covers [E] for damage.
If they are damaged, replace them.
• Check that the relief [F] and supply [G] ports are not
plugged.
If the small relief port becomes plugged, the brake pads
will drag on the disc. Blow the ports clean with com-
pressed air.
• Check the piston return springs [H] for any damage.
If a spring is damaged, replace it.
Front Master Cylinder [J]
Rear Master Cylinder [K]
BRAKES 12-23
Brake Disc
Brake Disc Removal
• Remove the wheels (see Front/Rear Wheel Removal in
the Wheels/Tires chapter).
• Remove the mounting bolts, and take off the disc.
Brake Disc Installation
• Install the brake disc on the wheel so that the marked side
[A] faces out.
the brake disc mounting bolts [B].
• Tighten:
Torque - Front Brake Disc Mounting Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Rear Brake Disc Mounting Bolts: 23 N·m (2.3
kgf·m, 17 ft·lb)
Brake Disc Inspection

• Visually inspect the disc [A].
If it is scratched or damaged, replace the disc.
• Measure the thickness of each disc at the point [B] where
it has worn the most.
[C] KX250ZD ∼ ZE
[D] KX250ZF
Disc Thickness
Standard:
Front 2.85 ∼ 3.15 mm (0.112 ∼ 0.124 in.)
Rear 3.85 ∼ 4.15 mm (0.152 ∼ 0.163 in.)
Service Limit:
Front 2.5 mm (0.10 in.)
Rear 3.5 mm (0.14 in.)
Replace the disc if it has worn past the service limit.
• Place a jack under the motorcycle so that the front/rear

wheel is raised off the ground.
•○Set up a dial gauge against the disc [A].
For the front disc, turn the handlebars fully to one side.
• Measure
slowly.
the disc runout while rotating [B] the wheel
Disc Runout
If the runout exceeds the service limit, replace the disc.
12-24 BRAKES
Brake Hose
Brake Hose Removal/Installation
• Refer to the Brake Hose Replacement in the Periodic
Brake Hose Inspection
• Refer to the Brake Hoses and Connections Inspection in
SUSPENSION 13-1
Suspension
Table of Contents
Exploded View........................................................................................................................ 13-2
Specifications ......................................................................................................................... 13-6
Special Tools .......................................................................................................................... 13-9
Front Fork ............................................................................................................................... 13-10
Air Pressure ...................................................................................................................... 13-10
Compression Damping Adjustment (Left Fork only) ......................................................... 13-10
Rebound Damping Adjustment (Left Fork only)................................................................ 13-11
Spring Preload Adjustment (Right Fork only).................................................................... 13-11
Oil Change ........................................................................................................................ 13-12
Front Fork Removal .......................................................................................................... 13-12
Front Fork Installation ....................................................................................................... 13-13
Front Fork Disassembly .................................................................................................... 13-13
Front Fork Assembly......................................................................................................... 13-14
Adjuster Assembly Inspection........................................................................................... 13-16
Base Valve Assembly Inspection ...................................................................................... 13-16
Cylinder Unit Inspection .................................................................................................... 13-16
Inner Tube Inspection ....................................................................................................... 13-16
Dust Seal Inspection ......................................................................................................... 13-17
Front Fork Spring Tension Inspection (Right Fork only).................................................... 13-17
Rear Shock Absorber ............................................................................................................. 13-18
Rebound Damping Adjustment ......................................................................................... 13-18
Compression Damping Adjustment .................................................................................. 13-18
Spring Preload Adjustment ............................................................................................... 13-20
Rear Shock Absorber Spring Tension Inspection ............................................................. 13-21
Rear Shock Absorber Removal ........................................................................................ 13-21
Rear Shock Absorber Installation ..................................................................................... 13-21 13
Rear Shock Absorber Spring Replacement ...................................................................... 13-21
Rear Shock Absorber Disassembly (Oil Change)............................................................. 13-22
Rear Shock Absorber Assembly ....................................................................................... 13-22
Rear Shock Absorber Inspection ...................................................................................... 13-22
Rear Shock Absorber Scrapping ...................................................................................... 13-23
Swingarm................................................................................................................................ 13-24
Swingarm Removal........................................................................................................... 13-24
Swingarm Installation........................................................................................................ 13-25
Swingarm Bearing Removal ............................................................................................. 13-25
Swingarm Bearing Installation .......................................................................................... 13-25
Drive Chain Guide, Guide Roller, Chain Slipper Wear Inspection .................................... 13-26
Swingarm Bearing, Sleeve Inspection .............................................................................. 13-26
Tie-Rod, Rocker Arm.............................................................................................................. 13-27
Tie-Rod Removal .............................................................................................................. 13-27
Tie-Rod Installation ........................................................................................................... 13-27
Rocker Arm Removal........................................................................................................ 13-27
Rocker Arm Installation..................................................................................................... 13-28
Tie-Rod and Rocker Arm Bearing Removal...................................................................... 13-28
Tie-Rod and Rocker Arm Bearing Installation................................................................... 13-29
Needle Bearing Inspection................................................................................................ 13-30
Uni-Trak Maintenance ............................................................................................................ 13-31
Uni-Trak Linkage Inspection ............................................................................................. 13-31
Tie-Rod and Rocker Arm Sleeve Wear Inspection ........................................................... 13-31
Tie-Rod and Rocker Arm Mounting Bolt Bend Inspection ................................................ 13-31
13-2 SUSPENSION
Exploded View
SUSPENSION 13-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Air Pressure Relief Screws 1.3 0.13 12 in·lb
2 Left Front Fork Base Valve Assembly 30 3.1 22
3 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L
4 Front Fork Clamp Bolts (Lower) 22 2.2 16 AL
5 Right Front Fork Spring Preload Adjuster 30 3.1 22
6 Left Front Fork Cylinder Unit 34 3.5 25
7 Right Front Fork Spring Adjuster Unit 34 3.5 25
Left Front Fork Adjuster Assembly
8 22 2.2 16
Locknut
9 Left Front Fork Adjuster Assembly 69 7.0 51 L
10 Right Front Fork Bottom Plug Locknut 22 2.2 16
11 Right Front Fork Bottom Plug 69 7.0 51 L
FO: Apply front fork oil.
G: Apply grease.
13-4 SUSPENSION
Exploded View
SUSPENSION 13-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Rear Shock Absorber Mounting Nut (Upper) 39 4.0 29 R
2 Rear Shock Absorber Mounting Nut (Lower) 34 3.5 25 R
3 Tie-Rod Mounting Nuts 59 6.0 44 R
4 Swingarm Pivot Shaft Nut 98 10.0 72 R
5 Rocker Arm Pivot Nut 59 6.0 44 R
6 Gas Reservoir Damping Adjuster Assembly 29.5 3.01 21.8
7 Rear Shock Absorber Spring Locknut 45 4.6 33
8 Piston Rod Locknut 37 3.8 27 R
G: Apply grease.
13-6 SUSPENSION
Specifications

Front Fork
KX250ZD
Air Pressure Atmospheric pressure – – –
Rebound Damping Adjustment 10 clicks counterclockwise (Adjustable Range)
(Left Fork only) (EUR, BR, TH) 12 clicks 20 ±4 clicks
(from the seated position adjuster counterclockwise
turned fully clockwise)
Compression Damping 8 clicks counterclockwise (Adjustable Range)
Adjustment (Left Fork only) (EUR, BR, TH) 10 clicks 22 ±6 clicks
Spring Preload Adjustment (Right 15 clicks clockwise (Adjustable Range)
Fork only) (EUR, BR, TH) 7 clicks clockwise 40 ±6 clicks
(from the seated position adjuster
turned fully counterclockwise)
(EUR, BR) 300 ±2.5 mL (10.14 300 ∼ 340 mL
±0.085 US oz.) (10.14 ∼ 11.50
US oz.)
230 ∼ 378 mL
(7.78 ∼ 12.78 US oz.)
Fork Spring Free Length (Right 660 mm (26.0 in.) 647 mm (25.5 in.)
Fork only)
KX250ZE
(Left Fork only) 20 ±4 clicks
Adjustment (Left Fork only) 22 ±6 clicks
Fork only) (EUR, BR, TH) 6 clicks clockwise 40 ±6 clicks
SUSPENSION 13-7
Specifications

300 ∼ 340 mL
(10.14 ∼ 11.50
US oz.)
218 ∼ 366 mL
(7.37 ∼ 12.37 US oz.)
Fork only)
KX250ZF
(Left Fork only) 20 ±4 clicks
Adjustment (Left Fork only) (EUR, BR, TH) 6 clicks 22 ±6 clicks
Fork only) 40 ±6 clicks
300 ∼ 340 mL
(10.14 ∼ 11.50
US oz.)
218 ∼ 366 mL
(7.37 ∼ 12.37 US oz.)
Fork only)
Rear Suspension (Uni-Trak):
Rear Shock Absorber
KX250ZD ∼ ZE
(from the seated position 22 ±5 clicks
adjuster turned fully clockwise)
Spring Preload Adjustment 127.2 mm (5.01 in.) (Adjustable Range)
(Lower surface of the adjusting 125.8 ∼ 139.5 mm
nut from the center of the upper (4.95 ∼ 5.49 in.)
mounting hole)
Rear Shock Spring Free 265 mm (10.4 in.) 260 mm (10.2 in.)
Length
13-8 SUSPENSION
Specifications

KX250ZF
(from the seated position 22 ±5 clicks
Spring Preload Adjustment 127.2 mm (5.01 in.) (Adjustable Range)
(Lower surface of the adjusting 125.8 ∼ 139.5 mm
nut from the center of the upper (4.95 ∼ 5.49 in.)
mounting hole)
Rear Shock Spring Free 265 mm (10.4 in.) 260 mm (10.2 in.)
Length
Gas Reservoir
KX250ZD ∼ ZE
High Speed Compression 2 turns out (Adjustable Range)
Damping Adjustment 4 ±1/2 turns out
(from the seated position
Low Speed Compression 12 clicks counterclockwise (Adjustable Range)
Damping Adjustment (EUR, BR, TH) 14 clicks 19 ±6 clicks
(from the seated position counterclockwise
adjuster turned fully clockwise) (KX250ZE)
Gas Pressure 980 kPa (10.0 kgf/cm², 142 psi) – – –
KX250ZF
High Speed Compression 2 turns out (Adjustable Range)
Damping Adjustment 4 ±1/2 turns out
Low Speed Compression 11 clicks counterclockwise (Adjustable Range)
Damping Adjustment 19 ±6 clicks
Gas Pressure 980 kPa (10.0 kgf/cm², 142 psi) – – –
Tie-Rod, Rocker Arm
Sleeve Outside Diameter:
Tie-Rod 19.987 ∼ 20.000 mm 19.85 mm (0.7815 in.)
(0.78689 ∼ 0.78740 in.)
Rocker Arm:
Large 19.987 ∼ 20.000 mm 19.85 mm (0.7815 in.)
(0.78689 ∼ 0.78740 in.)
Small 15.950 ∼ 16.000 mm 15.92 mm (0.6268 in.)
(0.62795 ∼ 0.62992 in.)
Rocker Arm Mounting Bolt TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008
Runout in.)
SUSPENSION 13-9
Special Tools
Oil Seal & Bearing Remover: Fork Oil Seal Driver, 48:
57001-1058 57001-1509
Hook Wrench R37.5, R42: Hook Wrench T=3.2 R37:

57001-1101 57001-1539
Bearing Driver Set: Jack Attachment:

57001-1129 57001-1608
Jack:
57001-1238
13-10 SUSPENSION
Front Fork
Air Pressure
The standard air pressure in the front fork legs is atmo-
spheric pressure. Air pressure in the fork legs increase with
normal use, so the fork action stiffens during operation. Re-
lease air pressure prior to each race through the air pres-
sure relief screw.
• Place the jack under the frame so that the front wheel is
• Remove the screws [A] on the base valve assembly (left

front fork) [B] and spring preload adjuster (right front fork)
[C] to let the air pressure equalize.
NOTE
○Do not use the sidestand when adjusting the air pres-
sure.
○Adjust the air pressure when the front forks are cold.
• Replace the O-rings with new ones.
• Tighten:
Torque - Air Pressure Relief Screws: 1.3 N·m (0.13 kgf·m,
12 in·lb)
Compression Damping Adjustment (Left Fork

only)
• Turn the adjuster [A] on the left front fork base valve as-
sembly [B] with a standard tip screwdriver until you feel a
click. Adjust the compression damping to suit your pref-
erence under special condition.
NOTICE
Do not force the compression damping adjuster
beyond the fully seated position, or the adjusting
mechanism may be damaged.
SUSPENSION 13-11
Front Fork
Seated position [A]: adjuster turned fully clockwise.
Compression Damping Adjuster Setting
Standard: 8 clicks [B] (KX250ZD)
(EUR, BR, TH) 10 clicks (KX250ZD)
9 clicks (KX250ZE)
7 clicks (KX250ZF)
(EUR, BR, TH) 6 clicks (KX250ZF)
Softer (Counterclockwise) [C]
Harder (Clockwise) [D]
*: Although you can turn the adjuster beyond the ad-
justable range, effecting no changes to damping
force, use it within the adjustable range.
Rebound Damping Adjustment (Left Fork only)
• Turn the adjuster [A] on the left front fork cylinder valve
[B] with a standard tip screwdriver until you feel a click.
Adjust the rebound damping to suit your preference under
special condition.
NOTICE
Do not force the rebound damping adjuster beyond
the fully seated position, or the adjusting mecha-
nism may be damaged.

Rebound Damping Adjuster Setting
12 clicks (KX250ZE)
10 clicks (KX250ZF)
Spring Preload Adjustment (Right Fork only)
• Turn the adjuster [A] with the wrench until you feel a click.
Adjust the spring preload to suit your preference under
special condition.
NOTICE
Do not force the spring preload adjuster beyond the
fully seated position, or the adjusting mechanism
may be damaged.
13-12 SUSPENSION
Front Fork
Seated position [A]: adjuster turned fully counterclock-
wise.
Spring Preload Adjuster Setting
8 clicks (KX250ZE ∼)
(EUR, BR, TH) 6 clicks (KX250ZE)
Harder (Clockwise) [C]
Softer (Counterclockwise) [D]
*: Although you can turn the adjuster beyond the
adjustable range, effecting no changes to spring
preload, use it within the adjustable range.
Oil Change
• Refer to the Front Fork Oil Change in the Periodic Main-
tenance chapter.
Front Fork Removal
• Remove:
chapter)
Bolts [A] and Brake Hose Clamps [B]
Bolts [C] and Guard [D]
Front Caliper Mounting Bolts [E]
Front Wheel (see Front Wheel Removal in the
• Put the caliper [A] on suitable stand [B] so that it does not
dangle.
• Loosen the upper [A] and lower [B] front fork clamp bolts.
SUSPENSION 13-13
Front Fork
• Pull out the front fork downward with a twisting motion [A].
Front Fork Installation

•○Install the front fork.
The length [A] between the upper end [B] of the outer tube
and steering stem head [C] is 5 mm (0.20 in.).
• Run the cables and hose according to the Cable, Wire,

and Hose Routing section in the Appendix chapter.
• Remove the front fork clamp bolts (upper) [A] and apply
a non-permanent locking agent to the bolts.
• Tighten:
Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 15 ft·lb)
Front Fork Clamp Bolts (Lower) [B]: 22 N·m (2.2
kgf·m, 16 ft·lb)
NOTE

Front Fork Disassembly
• Drain the fork oil (see Front Fork Oil Change in the Peri-
• Remove the locknut [A].
• Push out [C]
Wrap the piston rod end [B] with a vinyl tape.
• the piston rod [D].
13-14 SUSPENSION
Front Fork
• Separate
follows:
the inner tube [A] from the outer tube [B] as
○Slide up the spring band [C].

○Slide up the dust seal [D].
○Remove the retaining ring [A] from the outer tube.
○Grasp the tubes and stroke the inner tube up and down
[A] several times. The shock to fork seal separates the
inner tube from the outer tube.
• Remove:
Bushings [A]
Washer [B]
Oil Seal [C]
Retaining Ring [D]
Dust Seal [E]
Spring Band [F]
• Wipe off the oil from the removed parts.
NOTE
○Disassemble the right front fork in the same way.
Front Fork Assembly
• Replace the following parts with new ones:
Dust Seal [A] with Spring Band
Retaining Ring [B]
Oil Seal [C]
Bushings [D]
•Place an oil coated plastic bag [E] over the end of the
inner tube to protect the oil seals.
○The inner tube bushings groove has a sharp edge [F] that
cut out the sealing lip of the seals as they are pushed
down over the inner tube.
•Apply grease to the oil seal.
•Install in order these parts on the inner tube.
SUSPENSION 13-15
Front Fork
• When assembling the new outer tube bushings, washer

and new oil seal [A], hold the oil seal against the new one,
and tap the oil seal with the fork oil seal driver [B] until it
stops.
Special Tool - Fork Oil Seal Driver, 48: 57001-1509
• Install the retaining ring to the outer tube.
• band on the
Push the dust seal into the outer tube, and put the spring
dust seal.
•○Insert the piston rod [A] into the fork cylinder [B].
Wrap the piston rod end with a vinyl tape.
○Push in [A] the piston rod with a suitable tool [B].

• Remove a vinyl tape and install the locknut [C].
NOTE
○Assemble the right front fork in the same way.
• Pour the fork oil (see Front Fork Oil Change in the Periodic
13-16 SUSPENSION
Front Fork
Adjuster Assembly Inspection
• Inspect the adjuster assembly [A] and push rod (left front
fork only) [B] for damage.
If they are damaged, replace them with new ones.
• Replace the O-ring [C] on the adjuster assembly with a
new one.
Base Valve Assembly Inspection

• Inspect the threads portion [A] and spring [B] of base
valve assembly [C] for damage.
If they are damaged, replace the base valve assembly
with a new one.
• Replace the O-rings [D] with new ones.
Cylinder Unit Inspection

• Inspect the piston rods [A] of the cylinder unit [B]/spring
adjuster unit [C] for scratches or bending.
If it has scratches or is bent, replace the cylinder unit
and/or spring adjuster unit with a new one.
Inner Tube Inspection

• Visually inspect the inner tube [A].
If there is any damage, replace the inner tube. Since
damage to the inner tube damages the oil seal and dust
seal, replace the oil seal and dust seal whenever the inner
tube is replaced.
NOTICE
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
SUSPENSION 13-17
Front Fork
• Temporarily assemble the inner [A] and outer [B] tubes,

and pump them back and forth manually to check for
smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident resulting in seri-
ous injury or death. Replace a badly bent or dam-
aged inner or outer tube and inspect the other tube
carefully before reusing it.
Dust Seal Inspection

• Inspect
damage.
the dust seal [A] for any signs of deterioration or
Replace it if necessary.
Front Fork Spring Tension Inspection (Right Fork

only)
• Since a spring becomes shorter as it weakens, check its
free length [A] to determine its condition.
If the spring is shorter than the service limit, it must be
replaced.
Fork Spring Free Length
Standard: 660 mm (26.0 in.)
13-18 SUSPENSION
Rear Shock Absorber
To suit to various riding conditions, the spring preload of
the shock absorber can be adjusted or the spring can be
replaced with an optional one. Also the damping force can
be adjusted easily so changing oil viscosity unnecessary.
Rebound Damping Adjustment
• Turn the rebound damping adjuster [A] on the rear shock
absorber lower end with a standard tip screwdriver until
you feel a click.
If the damper setting feels too soft or too stiff, adjust it in
accordance with the following table.
NOTICE
Do not force the rebound damping adjuster beyond
the fully seated position, or the adjusting mecha-
nism may be damaged.

Rebound Damping Adjuster Setting
Standard: 12 clicks [B] (KX250ZD ∼ ZE)
14 clicks (KX250ZF)
NOTE
○Adjustment of the rebound damping adjuster for the rear
suspension will slightly affect the compression damping
force. Always make any damping adjustments in small
steps and test their effects before using them in com-
petition.
Compression Damping Adjustment
There are two adjustments you can make to the rear
shock absorber gas reservoir.
High Speed Compression Damping Adjuster [A]
Low Speed Compression Damping Adjuster [B]
SUSPENSION 13-19
Rear Shock Absorber
• Adjust the high speed compression damping, turn the

high speed compression damping adjuster with a wrench.
If the damping feels too soft or too stiff, adjust it in accor-
dance with the following table.
NOTICE
High Speed Compression Damping Adjuster Setting
Standard: 2 turns out [B]
• Adjust the low speed compression damping, turn the low

speed compression damping adjuster with a standard tip
screwdriver.
If the damping feels too soft or too stiff, adjust it in accor-
dance with the following table.
NOTICE
Low Speed Compression Damping Adjuster Setting
Standard: 12 clicks [B]
(EUR, BR, TH) 14 clicks (KX250ZE)
11 clicks (KX250ZF)
NOTE
○Adjustment of the compression damping adjusters for
the rear suspension will slightly affect the rebound
damping force. Always make any damping adjust-
ments in small steps and test their effects before using
them in competition.
13-20 SUSPENSION
Rear Shock Absorber
Spring Preload Adjustment
• Remove:
Side Covers (see Side Cover Removal in the Frame
chapter)
Muffler Body (see Muffler Body Removal in the Engine
Top End chapter)
chapter)
• Place the jack under the frame so that the rear wheel is
• Using the hook wrenches [A], loosen the locknut [B].

Special Tools - Hook Wrench R37.5, R42: 57001-1101
Hook Wrench T=3.2 R37: 57001-1539
• Using the hook wrench [A], turn the adjusting nut [B] as
required. Turning the adjusting nut downward marks the
spring action harder and upward softer.
Special Tool - Hook Wrench R37.5, R42: 57001-1101
Spring Preload Adjustment

(Lower surface of the adjusting nut from the center of
the upper mounting hole [A])
Standard: 127.2 mm (5.01 in.)
Adjustable 125.8 ∼ 139.5 mm (4.95 ∼ 5.49 in.)
Range:
• Tighten:
Torque - Rear Shock Absorber Spring Locknut: 45 N·m (4.6
kgf·m, 33 ft·lb)
• After adjusting, move the spring up and down to make
sure that the spring is seated.
SUSPENSION 13-21
Rear Shock Absorber
Rear Shock Absorber Spring Tension Inspection
• Since the spring becomes shorter as it weakens, check
its free length [A] to determine its condition.
Shock Absorber Spring Free Length
Standard: 265 mm (10.4 in.)
If the free length falls below the service limit, replace the
spring.
Rear Shock Absorber Removal

• Remove:
Side Covers (see Side Cover Removal in the Frame
chapter)
Top End chapter)
chapter)
NOTICE
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on a bolt could
damage the bolt, sleeve, and bearing.
• Remove the upper mounting bolt and nut [A].

• Remove the lower mounting bolt and nut [B], and take off
the rear shock absorber.
○Take care not to hit the rear shock absorber to the
swingarm.
Rear Shock Absorber Installation
• Replace
ones.
the rear shock absorber mounting nuts with new
• Apply plenty of grease to the oil seals and grease seals.

• Tighten:the rear shock absorber.
Install
•
Torque - Rear Shock Absorber Mounting Nut (Upper): 39
Rear Shock Absorber Mounting Nut (Lower): 34
Rear Shock Absorber Spring Replacement
In addition to the standard spring, heavy and light springs
are available. If the standard spring is improper for your
purpose, select a proper one according to the rider’s weight
or course conditions.
sorber Removal).
• Clean the threaded portion on the upper of the rear shock
absorber.
13-22 SUSPENSION
Rear Shock Absorber
• Hold the upper end of the rear shock absorber in a vise

with soft jaws [A] or a heavy cloth.
• Using the hook wrenches [B], loosen the locknut [C] and
turn the adjusting nut all way up.
Special Tools - Hook Wrench R37.5, R42: 57001-1101
Hook Wrench T=3.2 R37: 57001-1539
• Slide the spring seat [A].

• the springtheseat
Remove circlip [B] from the shock absorber and lift off
and spring [C].
• Remove the rear shock absorber from the vise.
•○Exchange the spring for an optional part.

Install the spring so that large diameter end [A] faces up-
ward.
• Install the spring seat and new circlip.
• Adjust the spring preload (see Spring Preload Adjust-
ment).
• Install the rear shock absorber (see Rear Shock Absorber
Installation).
Rear Shock Absorber Disassembly (Oil Change)
• Refer to the Rear Shock Absorber Oil Change in the Pe-
Rear Shock Absorber Assembly
• Refer to the Rear Shock Absorber Oil Change in the Pe-
Rear Shock Absorber Inspection
sorber Removal).
• Visually inspect the following items.
Oil Leakage
Crack or Dent
If there is any damage to the rear shock absorber, replace
it.
• Visually inspect the oil seal [A].
If it show any signs of damage, replace it.
SUSPENSION 13-23
Rear Shock Absorber
Rear Shock Absorber Scrapping
WARNING
Pressurized nitrogen may explode when heated.
The rear shock contains nitrogen gas. To avoid
an explosion, do not incinerate the shock body
without first releasing the nitrogen and removing
the shraeder valve.

sorber Removal).
• Insert a suitable tool into the gas reservoir cap hole [A] to
release the nitrogen gas.
13-24 SUSPENSION
Swingarm
Swingarm Removal
• Remove:
Rear Wheel (see Rear Wheel Removal in the
Rear Flap (see Rear Flap Removal in the Frame chap-
ter)
Brake Pedal Bolt and Return Spring (see Brake Pedal
Removal in the Brakes chapter)
• Remove:
Bolts [A] and Nuts
Chain Guide Plate [B]
Chain Guide [C]
Screws [D] and Brake Hose Clamps [E]
• Put the caliper [A] on suitable stand [B] so that it does not
dangle.
• Remove the rocker arm pivot nut and bolt [A].

• Pull out the
Remove the swingarm pivot shaft nut [B].
• swingarm [D].swingarm pivot shaft [C], and remove the
NOTICE
When pulling out the mounting bolts, lift the
swingarm slightly. Forcing or tapping on a bolt
could damage the bolt, sleeve, and bearing.
• Remove the screws [A].

• Remove the chain slipper [B] from the swingarm.
SUSPENSION 13-25
Swingarm
Swingarm Installation
• Apply plenty of grease to the inside of the needle bear-
ings, sleeves, and grease seals.
• Apply
screws.
a non-permanent locking agent to the chain slipper
• Install the chain slipper, and tighten the screws.

Rocker Arm Pivot Nut
• Apply 2-stroke oil to the threads of the rocker arm pivot
bolt.
• Install the swingarm.
• Tighten:
Torque - Swingarm Pivot Shaft Nut: 98 N·m (10.0 kgf·m, 72
ft·lb)
Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
Swingarm Bearing Removal
• Remove:
Swingarm (see Swingarm Removal)
Collars [A]
Grease Seals [B]
Sleeves [C]
Needle Bearings [D]
• Remove the needle bearings [E] using the oil seal & bear-
ing remover.
Special Tool - Oil Seal & Bearing Remover: 57001-1058
Swingarm Bearing Installation

• Replace
ones.
the needle bearings and grease seals with new
• Apply plenty of grease to the grease seals, and needle

bearings [A] [B].
NOTE
○Install the needle bearings so that the manufacturer’s
marks face out.
○Install the grease seals so that the deep groove side of
the rip inward.
• Install the needle bearings, grease seals [C], sleeve [D]
and collar [E].
○The installation procedure is the same as the counter
side.
13-26 SUSPENSION
Swingarm
Drive Chain Guide, Guide Roller, Chain Slipper
Wear Inspection
• Visually inspect the drive chain guide [A] and replace it if
excessively worn or damaged.
• Visually inspect the upper and lower chain guide rollers

[A] and replace them if excessively worn or damaged.
• Visually inspect the chain slipper [A] on the swingarm and

replace it if excessively worn or damaged.
Swingarm Bearing, Sleeve Inspection

NOTICE
•○Inspect the needle bearing [A] installed in the swingarm.

The rollers in a bearing normally wear very little, and wear
is difficult to measure. Instead of measuring, visually
inspect the bearing for abrasion, discoloration, or other
damage.
If the needle bearing and sleeve show any signs of ab-
normal wear, discoloration, or damage, replace them as
a set.
SUSPENSION 13-27
Tie-Rod, Rocker Arm
Tie-Rod Removal
• Remove:
Nut [A]
Lower Chain Guide Roller [B]
• Remove:
Rear Tie-Rod Mounting Bolt and Nut [A]
Front Tie-Rod Mounting Bolt and Nut [B]
Tie-Rod [C]
NOTICE
Tie-Rod Installation
Tie-Rod Mounting Nuts
Lower Chain Guide Roller Nut
• Apply plenty of grease to the oil seals.
• Install:
Collars
Tie-Rod
• Apply 2-stroke oil to the threads of the tie-rod mounting
bolts.
• Tighten:
Torque - Tie-Rod Mounting Nuts: 59 N·m (6.0 kgf·m, 44
ft·lb)
• Install the lower chain guide roller, and tighten the nut.
Rocker Arm Removal
• Using the jack under the frame, raise the rear wheel off
the ground.
• Remove the rear tie-rod mounting bolt and nut [A].

NOTICE
13-28 SUSPENSION
Tie-Rod, Rocker Arm
• Remove:
Rear Shock Absorber Bolt and Nut (Lower) [A]
Rocker Arm Pivot Bolt and Nut [B]
Rocker Arm [C]
Rocker Arm Installation

Rear Shock Absorber Mounting Nut (Lower)
Rocker Arm Pivot Nut
Tie-Rod Mounting Nut
• Apply plenty of grease to the needle bearings, oil seals
and grease seals.
• Install:
Collars and Sleeve
Rocker Arm
• Apply 2-stroke oil to the threads of the rocker arm pivot
bolt and tie-rod mounting bolt.
• Tighten:
Torque - Rear Shock Absorber Mounting Nut (Lower): 34
Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
Tie-Rod Mounting Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
Tie-Rod and Rocker Arm Bearing Removal

• Remove:
Tie-Rod (see Tie-Rod Removal)
Rocker Arm (see Rocker Arm Removal)
Collars [A]
Sleeves [B]
Oil Seals [C]
Grease Seals [D]
• Remove the needle bearing [E], using the bearing driver
set.
• Remove the needle bearings [F], using the oil seal & bear-
ing remover.
Special Tools - Oil Seal & Bearing Remover: 57001-1058
Bearing Driver Set: 57001-1129
SUSPENSION 13-29
Tie-Rod, Rocker Arm
Tie-Rod and Rocker Arm Bearing Installation
• Replace the needle bearings, oil seals and grease seals
with new ones.
• Apply plenty of grease to the oil seals, grease seals and
needle bearings.
NOTE
○Install the bearings so that the marked side faces out.
○Install the oil seals so that the deep groove side faces
inward.
○Install the grease seals so that the groove side faces
outward.
• Install the needle bearings [A] [B], oil seals [C] and grease
seals [D] so that their positions are as shown.
○The other side is also the same procedures.
Front [E]
Right Side [F]
Left Side [G]
Rear Shock Absorber [H]
Tie-Rod [I]
Rocker Arm [J]
Deep Groove [K]
Groove [L]
13-30 SUSPENSION
Tie-Rod, Rocker Arm
Needle Bearing Inspection
NOTICE
• Inspect the needle bearings installed in the tie-rod and

rocker arm.
○The needle bearing normally wear very little, and wear
is difficult to measure. Instead of measuring, visually in-
spect the bearings for abrasion, discoloration, or other
damage.
If there is any doubt as to the condition of either needle
bearing, replace the bearing and sleeve as a set.
SUSPENSION 13-31
Uni-Trak Maintenance
Uni-Trak Linkage Inspection
• Refer to the Swingarm and Uni-Trak Linkage Inspection
Tie-Rod and Rocker Arm Sleeve Wear Inspection
• Pull out the sleeves [A] of the tie-rod and rocker arm.
• Measure the outside diameter of the sleeve.
Sleeve Outside Diameter
Standard:
Tie-Rod 19.987 ∼ 20.000 mm (0.78689 ∼ 0.78740 in.)
Rocker Arm:
Large 19.987 ∼ 20.000 mm (0.78689 ∼ 0.78740 in.)
Small 15.950 ∼ 16.000 mm (0.62795 ∼ 0.62992 in.)
Service Limit:
Tie-Rod 19.85 mm (0.7815 in.)
Rocker Arm:
Large 19.85 mm (0.7815 in.)
Small 15.92 mm (0.6268 in.)
If the sleeve is worn past the service limit, replace the
sleeve.
Tie-Rod and Rocker Arm Mounting Bolt Bend

Inspection
A bent bolt causes vibration, poor handling, and instabil-
ity.
• To measure the bolt runout, remove the bolt, place it in V
blocks, and set a dial gauge to the bolt at a point halfway
between the blocks.
• Turn [A] the bolt to measure the runout.
○The amount of dial variation is the amount of runout.
Rocker Arm Mounting Bolt Runout
If runout exceeds the service limit, replace the bolt.
STEERING 14-1
Steering
Table of Contents
Exploded View........................................................................................................................ 14-2
Special Tools .......................................................................................................................... 14-4
Steering .................................................................................................................................. 14-5
Steering Inspection ........................................................................................................... 14-5
Steering Adjustment.......................................................................................................... 14-5
Steering Stem, Stem Bearing Removal ............................................................................ 14-5
Steering Stem, Stem Bearing Installation ......................................................................... 14-6
Stem Bearing Lubrication.................................................................................................. 14-8
Stem Bearing Wear, Damage Inspection.......................................................................... 14-8
Stem Warp Inspection....................................................................................................... 14-8
Handlebars ............................................................................................................................. 14-9
Handlebar Removal .......................................................................................................... 14-9
Handlebar Installation ....................................................................................................... 14-10
Handlebar Position Adjustment (KX250ZF) ...................................................................... 14-11
14
14-2 STEERING
Exploded View
STEERING 14-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Handlebar Clamp Bolts 25 2.5 18 AL, 2T
2 Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L
3 Steering Stem Head Nut 98 10.0 72
4 Handlebar Holder Nuts 34 3.5 25 R
5 Steering Stem Nut 4.9 0.50 43 in·lb T
6 Brake Hose Clamp Bolt 3.0 0.31 27 in·lb
7 Front Fork Clamp Bolts (Lower) 22 2.2 16 AL
8. KX250ZF
AD: Apply adhesive.
G: Apply grease.
T: First, tighten the stem nut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and retighten
it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.
14-4 STEERING
Special Tools
Bearing Puller: Head Pipe Outer Race Driver, 54.5:
57001-135 57001-1077
Steering Stem Bearing Driver: Steering Stem Nut Wrench:

57001-137 57001-1100
Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover ID > 37 mm:
57001-1074 57001-1107
Head Pipe Outer Race Press Shaft: Bearing Puller:

57001-1075 57001-1575
Head Pipe Outer Race Driver, 51.5:

57001-1076
STEERING 14-5
Steering
Steering Inspection
• Refer to the Steering Inspection in the Periodic Mainte-
nance chapter.
Steering Adjustment
• Refer to the Steering Adjustment in the Periodic Mainte-
nance chapter.
Steering Stem, Stem Bearing Removal
• Remove:
Frame chapter)
Handlebar Pad [B]
• Disconnect:
• Remove:
Brake Hose Clamp Bolt [A]
Handlebar Clamp Bolts [B]
Handlebar Clamps [C]
Handlebars [D]
Steering Stem Head Nut [E] and Washer
• Remove:
Front Wheel (see Front Wheel Removal in the
Front Fender (see Front Fender Removal in the Frame
chapter)
Front Forks (see Front Fork Removal in the Suspension
chapter)
Steering Stem Head [A]
• Hold the stem base [A] by hand, and remove the steering
stem nut [B] with the steering stem nut wrench [C].
• Remove the steering stem [D] and stem base from the
head pipe.
14-6 STEERING
Steering
• Remove the upper stem bearing inner race (tapered roller

bearing) [A].
•○Drive out the bearing outer races from the head pipe.
Remove the outer races pressed into the head pipe, using
the head pipe outer race remover [A], and hammer the
head pipe outer race remover to drive it out.
Special Tool - Head Pipe Outer Race Remover ID > 37 mm:
57001-1107
NOTE
○If either steering stem bearing is damaged, it is recom-
mended that both the upper and lower bearing (includ-
ing outer races) should be replaced with new ones.
• Remove the lower stem bearing inner race (tapered roller

bearing) [A] with its grease seal from the stem using bear-
ing pullers.
Special Tools - Bearing Puller: 57001-135
Bearing Puller: 57001-1575
○Assemble the bearing puller (Special Tool: 57001-1575).
○Insert the each half-split base [B] under the bottom of
bearing inner race and connect the both bases by tight-
ening the bolts [C] and nuts [D].
NOTE
○Tighten evenly two bases by the two stud bolts.
○Assemble the parts of the bearing puller (Special Tool:
57001-135).
Stud Bolts [E]
Arm [F]
Center Bolt [G]
Adapter [H]
○Turn the center bolt by a wrench and pull the bearing inner
race.
Steering Stem, Stem Bearing Installation
• Replace the bearing outer races with new ones.
• Drive the outertoraces
Apply grease the outer races.
• with the special tools.into the head pipe at the same time
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver, 51.5 [B]:
57001-1076
Head Pipe Outer Race Driver, 54.5 [C]:
57001-1077
STEERING 14-7
Steering
• Replace the inner races with new ones.

• drive it onto thetostem
Apply grease the lower tapered roller bearing [A], and
with the steering stem bearing driver
[B] and adapter [C].
Special Tools - Steering Stem Bearing Driver: 57001-137
Steering Stem Bearing Driver Adapter,
34.5: 57001-1074
• Apply grease to the upper tapered roller bearing, and in-

stall it in the head pipe.
• Install the stem through the head pipe and upper bearing,
and hand-tighten the stem nut while pushing up the stem
base.
•Install the stem head and washer, and tighten the stem
head nut lightly.
•Settle the bearing in place as follows;
○Tighten the stem nut to 39 N·m (4.0 kgf·m, 29 ft·lb) of
torque (To tighten the steering stem nut to the specified
torque, hook the wrench [A] on the stem nut, and pull the
wrench at the hole by 22.2 kgf force [B] in the direction
shown.).
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
○Again back out the stem nut a fraction of a turn until it
turns lightly.
○Turn the stem nut lightly clockwise until it just becomes
hard to turn. Do not overtighten, or the steering will be
too tight.
Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
• Install the stem head.

• nut. the washer, and temporary tighten the stem head
Install
• Install the front forks (see Front Fork Installation in the

Suspension chapter).
• Apply a non-permanent locking agent to the front fork
clamp bolts (upper).
• Tighten:
Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 15 ft·lb)
Steering Stem Head Nut: 98 N·m (10.0 kgf·m, 72
ft·lb)
Front Fork Clamp Bolts (Lower): 22 N·m (2.2
kgf·m, 16 ft·lb)
NOTE
○Tighten the fork clamp bolts (upper) first, next the stem
head nut, last the fork clamp bolts (lower).
14-8 STEERING
Steering

Torque - Brake Hose Clamp Bolt: 3.0 N·m (0.31 kgf·m, 27
in·lb)
WARNING
If the handlebar does not turn to the steering stop it
may cause an accident resulting in injury or death.
Be sure the cables, harnesses and hoses are routed
properly and do not interfere with handlebar move-
ment (see Cable, Wire, and Hose Routing section in
the Appendix chapter).
• Check and Adjust:

Steering
Front Brake
Clutch Cable
Throttle Cable
Stem Bearing Lubrication
• Refer to the Steering Stem Bearing Lubrication in the Pe-
Stem Bearing Wear, Damage Inspection
• Using a high flash-point solvent, wash the upper and
lower tapered rollers in the cages, and wipe the upper
and lower outer races, which are press-fitted into the
head pipe, clean off grease and dirt.
• Visually check the outer race and the rollers.
Replace the bearing assembly if it show damage.
Stem Warp Inspection
• Whenever the steering stem is removed, or if the steering
cannot be adjusted for smooth action, check the steering
stem shaft [A] for straightness.
If the steering stem shaft is bent, replace the steering
stem.
STEERING 14-9
Handlebars
Handlebar Removal
• Remove:
Frame chapter)
Handlebar Pad [B]
• Disconnect:
• Remove:
Clutch Lever Assembly [A]
Engine Stop Switch [B]
Band [C]
Left Handlebar Grip [D]
• For
[A].
KX250ZE ∼, remove the launch control mode button
• Remove:
Throttle Grip Assy [A] (see Throttle Cable Replacement
in the Fuel System (DFI) chapter)
Front Master Cylinder [B] (see Front Master Cylinder Re-
moval in the Brakes chapter)
• Remove:
Handlebar Clamp Bolts [A]
Handlebar Clamps [B]
Handlebars [C]
• Check the handlebars for bends or cracks.
If the handlebars was bended or cracked, replace it.
14-10 STEERING
Handlebars
Handlebar Installation
• Apply adhesive cement to the innermost area of the left
handlebar grip and all-around inner surface of the left han-
dlebar grip hole entrance and also apply it to the roulette
area on the handlebars.
•The left handlebar grip must be installed with the triangle
mark [A] upward.
○When installing the left handlebar grip, rotate the grip
more than once first, and then remove and install the grip
alternately more than three times to spread adhesive ce-
ment. Make sure that adhesive cement has been spread
evenly.
○After installation, hold the left handlebar grip area at more
than three points to make the left handlebar grip stick to
the handlebars.
•Install the clutch lever assembly (see Clutch Lever Instal-
lation in the Clutch chapter).
•Install the engine stop switch.
•○For KX250ZE ∼, note the following.

Install the launch control mode button [A] as shown.
Clutch Lever Holder Assembly [B]
5 ∼ 10 mm (0.2 ∼ 0.4 in.) [C]
• Apply grease to the throttle cable upper end and clutch

cable upper end.
• Apply
bars.
2-stroke oil to the edge (slash area) of the handle-
120 mm (4.72 in.) [A]
• Install the throttle grip assembly so that the grip [A] is in

as far as it will go.
○Position the throttle grip assembly so that the cable gate-
way [B] of the throttle case is above the handlebars.
• Install the front master cylinder (see Front Master Cylinder
Installation in the Brakes chapter).
STEERING 14-11
Handlebars
• Install
follows.
the handlebars [A] on the steering stem head as
○The handlebars angle position can be adjusted to suit

your preference using the gauge marks [B].
○Position the handlebars so that the gauge marks is equal
positions [C].
Bridge Bar [D]
• Apply 2-stroke oil to the handlebar clamp bolts.
• Install the handlebar clamps [E] and handlebar clamp
bolts [F].
•○Tighten the handlebar clamp bolts [A].

Equalize the front and rear gaps [B].
NOTE
Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Install:
Handlebar Pad [A]
Fuel Tank Breather Hose [B]
Number Plate [C] (see Number Plate Installation in the
Frame chapter)
Handlebar Position Adjustment (KX250ZF)

The handlebar position can be adjusted in four positions
back and forth.
Front Holes [A]
Rear Holes [B]
Handlebar holders [C]
To suit various riding positions, the handlebar holder po-
sition can be changed and the handlebar can be adjusted
by turning the handlebar holders around (180°).
• Remove the handlebar pad.

• Remove the handlebar clamp bolts [A], handlebar clamps
[B] and handlebar [C].
• Check the handlebar for damage or cracks.
If the handlebar is damage or cracks, replace it with a new
one.
14-12 STEERING
Handlebars
• Remove:
Handlebar Holder Nuts [A]
Flat Washers [B]
Round Washers [C]
Handlebar Holders [D]
Dampers [E]
• Select the handlebar position and install the upper and

lower dampers [A] into the hole [B] of the steering stem
head [C] so that the flat surface [D] of dampers fit the flat
surface [E] of the steering stem head hole.
• Install the round washer [A] and handlebar holder [B] in

the suitable direction.
○Install the round washer so that the round part fits on the
damper.
• Put the handlebar [A] on the handlebar holders [B].

• Temporarily install the handlebar clamps [C] and tighten
the handlebar clamp bolts [D].
• Replace the handlebar holder nuts [E] with new ones.
• dlebar holder
Install the round washers [F], flat washers [G], and han-
nuts .
○Install the round washers so that the round part fits under
the dampers.
• Tighten:
Torque - Handlebar Holder Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Install the handlebar (see Handlebar Installation).
FRAME 15-1
Frame
Table of Contents
Exploded View........................................................................................................................ 15-2
Frame ..................................................................................................................................... 15-4
Frame Inspection .............................................................................................................. 15-4
Rear Frame Removal........................................................................................................ 15-4
Rear Frame Installation..................................................................................................... 15-4
Engine Guards Removal................................................................................................... 15-5
Engine Guards Installation................................................................................................ 15-5
Seat ........................................................................................................................................ 15-6
Seat Removal ................................................................................................................... 15-6
Seat Installation ................................................................................................................ 15-6
Side Covers ............................................................................................................................ 15-7
Side Cover Removal ......................................................................................................... 15-7
Side Cover Installation ...................................................................................................... 15-7
Radiator Shroud ..................................................................................................................... 15-8
Radiator Shroud Removal................................................................................................. 15-8
Radiator Shroud Installation.............................................................................................. 15-8
Number Plate.......................................................................................................................... 15-9
Number Plate Removal..................................................................................................... 15-9
Number Plate Installation.................................................................................................. 15-9
Fender .................................................................................................................................... 15-10
Front Fender Removal ...................................................................................................... 15-10
Front Fender Installation ................................................................................................... 15-10
Rear Fender Removal/Installation .................................................................................... 15-10
Rear Flap Removal/Installation......................................................................................... 15-10
Footpegs................................................................................................................................. 15-11
Footpeg Removal.............................................................................................................. 15-11
Footpeg Installation........................................................................................................... 15-11
Footpeg Height Adjustment (KX250ZF)............................................................................ 15-12
15
15-2 FRAME
Exploded View
FRAME 15-3
Exploded View
Torque
N·m kgf·m ft·lb
Footpeg Bracket Bolts (Upper) (KX250ZD ∼ ZE) 54 5.5 40 L
1
Footpeg Bracket Bolts (Upper) (KX250ZF) 34 3.5 25 L
2 Footpeg Bracket Bolts (Lower) 16.5 1.68 12.2 L
3 Rear Frame Mounting Bolts 34 3.5 25
4. KX250ZF
G: Apply grease.
15-4 FRAME
Frame
Frame Inspection
• Refer to the Frame Inspection in the Periodic Mainte-
nance chapter.
Rear Frame Removal
• Remove:
Seat (see Seat Removal)
Side Covers (see Side Cover Removal)
Top End chapter)
Rear Fender (see Rear Fender Removal)
Rear Flap (see Rear Flap Removal)
Upstream Injector Connector [A]
Fuel Hose [B] (see Fuel Hose Replacement in the Peri-
odic Maintenance chapter)
• Disconnect
[A].
the intake air temperature sensor connector
• Loosen the air cleaner duct clamp bolt [B].
• Remove the rear frame mounting bolts [A] on both sides.

• housing. rear frame [B] together with the air cleaner
Take off the
○Separate the air cleaner duct from the throttle body assy.
○Take care not to damage the frame and rear shock ab-
sorber with the air cleaner duct clamp.
Rear Frame Installation

• Fit the claw [A] of the clamp and the groove [B] of the air
cleaner duct.
•○Install the rear frame.
Insert the duct onto the throttle body assy.
• Tighten:
Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
• Tighten the air cleaner duct clamp bolt.
FRAME 15-5
Frame
Engine Guards Removal
• Remove the engine guards.
Right Engine Guard [A]
Left Engine Guard [B]
Lower Engine Guard [C]
Bolts [D]
Collars [E]
Engine Guards Installation

•○Installation is the reverse of removal.
Fit the projection [A] of the right engine guard and hole [B]
of the frame.
○Fit the left engine guard similarly.
15-6 FRAME
Seat
Seat Removal
• Remove the side cover bolt [A] on both sides.
• Spread [A] the side covers lightly.

• Take off the seat [B] backward [C].
Seat Installation
•○Install the seat.
Insert the hooks [A] of the seat under the flange collar [B]
and brackets [C].
○Take care not to damage the side covers with the bracket
of seat.
• Tighten the side cover bolts.
FRAME 15-7
Side Covers
Side Cover Removal
•○Remove the bolts [A] and take off the side cover [B].
Clear the side cover tabs [C] from the air cleaner housing.
Side Cover Installation

• Stick the pad [A] on the inside of the right side cover.
• Install the damper [B] securely.
•○Install the side covers.

Insert the tabs [A] of the side cover into the slots [B] of the
air cleaner housing.
○Insert the side cover rib [A] between the rear fender [B]
and the rear frame [C].
• Tighten the bolts.
15-8 FRAME
Radiator Shroud
Radiator Shroud Removal
• Remove:
Bolts [A]
Radiator Shroud [B]
○Clear the radiator shroud tabs [C] from the air cleaner
housing.
Radiator Shroud Installation

•○Install the radiator shrouds.
Insert the tabs [A] of the radiator shroud into the slots [B]
of the air cleaner housing.
• Temporarily install the bolts as shown sequence [1 ∼ 4].

L = 13 mm (0.51 in.) [1 ∼ 3]
L = 20 mm (0.79 in.) [4]
• Tighten all bolts securely.
FRAME 15-9
Number Plate
Number Plate Removal
• Unlock the band [A] of the number plate [B].
• Remove the bolt [C].
• Clear the projections [D] and remove the number plate.
Number Plate Installation

• Fit the holes [A] of the number plate and projections [B]
of the steering stem base.
○Run the brake hose through the front of the number plate.
• Install the band to the handlebar pad, and tighten the bolt.
15-10 FRAME
Fender
Front Fender Removal
• Remove the bolts [A] and take off the front fender [B].
Front Fender Installation

• Temporarily install the front bolts [A] first, and then the
rear bolts [B].
• Tighten all bolts securely.
Rear Fender Removal/Installation

• Remove the side covers (see Side Cover Removal).
• Remove the bolts [A].
• Remove
fender [B].
the bolt [A] on both sides, and take off the rear
• Installation is the reverse of removal.
Rear Flap Removal/Installation

• Remove the screws [A] and take off the rear flap [B].
• Installation is the reverse of removal.
FRAME 15-11
Footpegs
Footpeg Removal
• Remove:
Cotter Pin [A]
Washer [B]
Pivot Pin [C]
Spring [D]
Footpeg [E]
Footpeg Bracket Bolts [F]
Footpeg Bracket [G]
Footpeg Installation
NOTE
○For KX250ZF, the footpeg can be adjusted in two posi-
tions, refer to the Footpeg Height Adjustment.

• bracket bolts
Apply a non-permanent locking agent to the footpeg
[A].
• Install the footpeg bracket [B], and tighten the bolts.
Torque - Footpeg Bracket Bolt (Upper) (KX250ZD ∼ ZE): 54
Footpeg Bracket Bolt (Upper) (KX250ZF): 34 N·m
(3.5 kgf·m, 25 ft·lb)
Footpeg Bracket Bolt (Lower): 16.5 N·m (1.68
kgf·m, 12.2 ft·lb)
• Apply grease to the pivot pin [C].
•○Insert the
Install the footpeg [D], spring [E] and pivot pin.
pivot pin from upper side.
• Install the washer [F] and new cotter pin [G].
• Bend the longer side [A] of the cotter pin.

15-12 FRAME
Footpegs
Footpeg Height Adjustment (KX250ZF)
○The footpeg can be adjusted in two positions.
Footpeg Bracket [A]
Bolts [B]
Bolt Holes [C]
Upper Position [D]
Lower Position [E]
• Remove:
Footpegs (see Footpeg Removal)
• Adjust the footpeg height.
NOTE
○Install the footpegs with same height on both sides. Do
not ride the motorcycle with footpegs installed unevenly.
○Adjust the position of the shift pedal and the brake pedal
to suit the rider’s preference.
○Installing the footpegs in the lower position will reduce
the amount of ground clearance and lean angle.
• Install:
Footpegs (see Footpeg Installation)
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Exploded View........................................................................................................................ 16-2
Specifications ......................................................................................................................... 16-4
Wiring Diagram (KX250ZD).................................................................................................... 16-7
Wiring Diagram (KX250ZE ∼) ................................................................................................. 16-10
Precautions............................................................................................................................. 16-12
Electrical Wiring...................................................................................................................... 16-13
Wiring Inspection .............................................................................................................. 16-13
Flywheel Magneto .................................................................................................................. 16-14
Magneto Cover Removal .................................................................................................. 16-14
Magneto Cover Installation ............................................................................................... 16-14
Flywheel Removal............................................................................................................. 16-14
Flywheel Installation.......................................................................................................... 16-15
Stator Coil Removal .......................................................................................................... 16-16
Stator Coil Installation ....................................................................................................... 16-16
Flywheel Magneto Inspection ........................................................................................... 16-17
Charging System .................................................................................................................... 16-19
Regulator/Rectifier Removal ............................................................................................. 16-19
Regulator/Rectifier Installation .......................................................................................... 16-19
Regulator/Rectifier Output Voltage Inspection .................................................................. 16-19
Regulator/Rectifier Inspection........................................................................................... 16-20
Capacitor Removal ........................................................................................................... 16-22
Capacitor Installation ........................................................................................................ 16-22
Capacitor Inspection ......................................................................................................... 16-22
Ignition Timing ........................................................................................................................ 16-23
Ignition Timing Inspection ................................................................................................. 16-23
Ignition System ....................................................................................................................... 16-24
Safety Instructions ............................................................................................................ 16-24
Ignition Coil Removal ........................................................................................................ 16-24
Ignition Coil Installation ..................................................................................................... 16-24
Ignition Coil Inspection...................................................................................................... 16-25
Spark Plug Cleaning and Inspection.................................................................................
Spark Plug Gap Inspection ...............................................................................................
16-26
16-26
16
Ignition Coil Primary Peak Voltage Check ........................................................................ 16-26
IC Igniter Inspection .......................................................................................................... 16-27
Crankshaft Sensor Peak Voltage Check........................................................................... 16-29
Crankshaft Sensor Inspection........................................................................................... 16-29
Engine Stop Switch System Check................................................................................... 16-30
Launch Control Mode Button System Check (KX250ZE ∼) .............................................. 16-30
DFI Setting Data Selection Connector Inspection............................................................. 16-30
Switches ................................................................................................................................. 16-32
Engine Stop Switch Inspection ......................................................................................... 16-32
Launch Control Mode Button Inspection (KX250ZE ∼) ..................................................... 16-32
Gear Position Switch Removal ......................................................................................... 16-32
Gear Position Switch Installation ...................................................................................... 16-32
Gear Position Switch Inspection ....................................................................................... 16-32
16-2 ELECTRICAL SYSTEM
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Regulator/Rectifier Nuts 10 1.02 89 in·lb R
2 Spark Plug 13 1.3 115 in·lb
3 Flywheel Nut Cap 3.5 0.36 31 in·lb
4 Magneto Cover Bolts 9.8 1.0 87 in·lb
5 Timing Inspection Cap 3.5 0.36 31 in·lb
6 Flywheel Nut 78.5 8.00 57.9
7 Stator Coil Bolts 9.8 1.0 87 in·lb L
8 Crankshaft Sensor Bolts 7.0 0.71 62 in·lb L
9 Gear Position Switch Screws 2.9 0.30 26 in·lb L
10. DFI Setting Data Selection Connectors
11. KX250ZD
12. KX250ZE ∼
G: Apply grease.
Si: Apply silicone grease.
SS: Apply silicone sealant.
Specifications
Item Standard
Flywheel Magneto
Magneto Output Voltage 37 V or more at 4 000 r/min (rpm)
Stator Coil Resistance 0.4 ∼ 1.1 Ω at 20°C (68°F)
Charging System
Charging Voltage (Regulator/Rectifier Output Voltage) 14.0 ∼ 14.5 V
Capacitor Internal Resistance see text
Ignition System
Ignition Timing 4° BTDC at 2 000 r/min (rpm)
Ignition Coil:
3 Needle Arcing Distance 7 mm (0.28 in.) or more
Primary Winding Resistance 0.28 ∼ 0.38 Ω at 20°C (68°F)
Secondary Winding Resistance 7.65 ∼ 10.4 kΩ at 20°C (68°F)
Primary Peak Voltage 150 V or more
Crankshaft Sensor Resistance 180 ∼ 280 Ω at 20°C (68°F)
Crankshaft Sensor Peak Voltage 2.5 V or more
Spark Plug:
Type NGK CPR8EB-9
Gap 0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)
Rotor Puller, M16/M18/M20/M22 × 1.5: Needle Adapter Set:
57001-1216 57001-1457
Timing Light: Flywheel Puller, M28 × 1.0:

57001-1241 57001-1471
Hand Tester: Grip:

57001-1394 57001-1591
Peak Voltage Adapter: Measuring Adapter:

57001-1415 57001-1700
Filler Cap Driver: Rotor Holder:

57001-1454 57001-1730
Liquid Gasket, TB1211F:
92104-0004
Wiring Diagram (KX250ZD)
Wiring Diagram (KX250ZE ∼)
Wiring Diagram (KX250ZE ∼)
Precautions
There are numbers of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
any electrical connections while the engine is running.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they too must be repaired or replaced,
or the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, etc. Poor
leads and bad connections will affect electrical system
operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
Electrical Wiring
Wiring Inspection
• Visually
etc.
inspect the wiring for signs of burning, fraying,
If any wiring is poor, replace the damaged wiring.

•Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
•Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect a digital meter between the ends of the leads.
If the digital meter does not read 0 Ω, the lead is defective.
Replace the lead or the wiring harness if necessary.
Flywheel Magneto
Magneto Cover Removal
• Remove:
the Frame chapter)
• Disconnect the magneto lead connector [A] from the main
harness.
• Open the clamps [A] then free the magneto lead [B].
• Bolt [C] and Engine Guard [D]
Remove:
Magneto Cover Bolts [E]

Magneto Cover [F]
Magneto Cover Installation

• Replace
gasket.
the gasket [A] with a new one and install the new
• Be sure to install the dowel pins [B].

• Apply silicone sealant to the area [A] to the magneto lead
grommet.
Sealant - Liquid Gasket, TB1211F: 92104-0004
• Tighten:
L = 35 mm (1.4 in.) [A]
L = 30 mm (1.2 in.) [B]
Torque - Magneto Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Hold the magneto lead and gear position switch lead with
the clamps [C] according to the Cable, Wire, and Hose
Routing section in the Appendix chapter.
• Connect the magneto lead connector.
Flywheel Removal
• Remove
moval).
the magneto cover (see Magneto Cover Re-
Flywheel Magneto
• Hold the flywheel steady with the rotor holder [A], and
remove the flywheel nut [B].
Special Tools - Grip [C]: 57001-1591
Rotor Holder: 57001-1730
• Install the flywheel puller [A] to the flywheel.

• Remove therotor
Install the puller [B] to the flywheel puller.
• rotor puller and
flywheel from the crankshaft by turning in the
tapping the head of the puller lightly with
a hammer, while holding the puller body steady. There is
a woodruff key in the crankshaft tapered portion.
Special Tools - Rotor Puller, M16/M18/M20/M22 × 1.5: 57001
-1216
Flywheel Puller, M28 × 1.0: 57001-1471
NOTICE
Never strike the grab bar or the flywheel itself. Strik-
ing the bar can bond it. If the flywheel is struck, the
magnets may lose their magnetism.
• Remove the woodruff key.

Flywheel Installation
that may be on the crankshaft taper [A] and in the hole
[B] of the flywheel. Dry them with a clean cloth.
• Fit the woodruff key [C] securely in the slot of the crank-
shaft.
• Install the flywheel according to the following procedures.
NOTE
○Confirm the flywheel fit or not to the crankshaft before
tightening it with specified torque.
○Install the flywheel.
○Hold the flywheel steady with the rotor holder, and tighten
the flywheel nut with 54 N·m (5.5 kgf·m, 40 ft·lb) of torque.
Special Tools - Grip: 57001-1591
○Remove the flywheel nut.
○Check the tightening torque with rotor puller.
Special Tool - Flywheel Puller, M28 × 1.0: 57001-1471
If the flywheel is not pulled out with 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, it is installed correctly.
If the flywheel is pulled out with under 20 N·m (2.0 kgf·m,
15 ft·lb) of drawing torque, clean off any oil dirt or flaw of
the crankshaft and flywheel tapered portion, and dry them
with a clean cloth. Then, confirm that it is not pulled out
with above torque.
Flywheel Magneto
• Hold the flywheel steady with the rotor holder, and tighten
the flywheel nut.
Special Tools - Grip: 57001-1591
Torque - Flywheel Nut: 78.5 N·m (8.00 kgf·m, 57.9 ft·lb)
• Install
tion).
the magneto cover (see Magneto Cover Installa-
Stator Coil Removal

• Remove:
Magneto Cover (see Magneto Cover Removal)
Stator Coil Bolts [A]
Crankshaft Sensor Bolts [B]
Holder [C]
Magneto Lead Grommet [D]
• Remove the stator coil [E] and crankshaft sensor [F] as a
set.
Stator Coil Installation

the stator coil bolts.
• Install the stator coil and crankshaft sensor as a set.
• Tighten:
Torque - Stator Coil Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the crankshaft sensor bolts.
• Install
bolts.
the holder [A] and tighten the crankshaft sensor
○Hold the magneto lead with the guide [B] of the holder.
Torque - Crankshaft Sensor Bolts: 7.0 N·m (0.71 kgf·m, 62
in·lb)
• Apply silicone sealant to the circumference of the mag-
neto lead grommet [C], and fit the grommet into the notch
[D] of the cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004
• Install
tion).
the magneto cover (see Magneto Cover Installa-
Flywheel Magneto
Flywheel Magneto Inspection
There are three types of magneto problems: short, open
(lead burned out), or loss in flywheel magnetism. A short or
open in one of the coil leads will result in either a low output,
or no output at all. A loss in flywheel magnetism, which may
be caused by dropping or hitting the flywheel by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
NOTE
○Be sure the prepared battery is fully charged.
• Check the magneto output voltage, do the following pro-
cedures.
○Remove the left radiator shroud (see Radiator Shroud Re-
○Disconnect the magneto lead connector (see Magneto
Cover Removal).
○Use the engine revolution tester [A] for high accuracy.
○Connect the measuring adapter [B] between the discon-
nected connectors.
○Connect a tester [C] to the magneto lead connector.
Main Harness [D]
Flywheel [E]
○Refer to the Self-diagnosis Procedures in the Fuel Sys-
tem (DFI) chapter, connect the 12 V battery to the main
harness.
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 3 measurements).
Table 1 Magneto Output Voltage at 4 000 r/min (rpm)
Connections
Reading
Tester (+) to Tester (–) to
One yellow lead Another yellow lead AC 37 V or more
If the output voltage shows the value in the table, the mag-
neto operates properly.
If the output voltage shows a much lower reading than that
given in the table indicates that the magneto is defective.
•To check the stator coil resistance as follows.
○Stop the engine.
○Connect the tester as shown in the table 2.
○Note the resistance readings (total 3 measurements).
Table 2 Stator Coil Resistance at 20°C (68°F)
Connections
Reading
One yellow lead Another yellow lead 0.4 ∼ 1.1 Ω
Flywheel Magneto
If there is more resistance than shown in the table, or no
tester reading (infinity), the stator has an open lead and
must be replaced. Much less than this resistance means
the stator is shorted, and must be replaced.
• Using the tester, measure the resistance between each
leads and chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating stator replacement.
If the stator coil has normal resistance, but the voltage
check showed the magneto to be defective; then the fly-
wheel have probably weakened, and the flywheel must
be replaced.
Charging System
Regulator/Rectifier Removal
• Remove:
(DFI) chapter)
• Open the clamp [A], and free the lead.
• Slide the dust cover [B].
• Disconnect the regulator/rectifier lead connector [C].
• Remove:
Regulator/Rectifier Nuts [A]
Regulator/Rectifier [B]
Regulator/Rectifier Installation
• Replace the regulator/rectifier nuts with new ones.
• Install the regulator/rectifier and tighten the nuts.
Torque - Regulator/Rectifier Nuts: 10 N·m (1.02 kgf·m, 89
in·lb)
• Run the regulator/rectifier lead according to the Cable,
• Connect the regulator/rectifier lead connector.
• Cover the lead connector with dust cover.
Regulator/Rectifier Output Voltage Inspection
NOTE
Charging System
• Connect the 12 V battery to the main harness (see Self

-diagnosis Procedures in the Fuel System (DFI) chapter).
• Connect a tester [A] to the battery terminals [B].
• engine speeds. But
Start the engine, and note the voltage readings at various
they must be kept the specified volt-
age.
Charging Voltage
Connections
Reading
Battery (+) Battery (–) DC 14.0 ∼ 14.5 V

If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
magneto output is insufficient for the loads. Check the
magneto and regulator/rectifier to determine which part is
defective.
Regulator/Rectifier Inspection
• Remove:
Regulator/Rectifier (see Regulator/Rectifier Removal)
• measurements
Set the hand tester to the × 1 kΩ range and make the
shown in the table.
Special Tool - Hand Tester: 57001-1394
• Connect the hand tester to the regulator/rectifier.
If the tester readings are not as specified, replace the
regulator/rectifier.
NOTICE
Use only Kawasaki Hand Tester 57001-1394 for this
test. A tester other than the Kawasaki Hand Tester
may show different readings.
If a megger or a meter with a large capacity battery
is used, the regulator/rectifier will be damaged.
Regulator/Rectifier Resistance (Unit: kΩ)

Tester (+) Lead Connection
Terminal A B C D E
A – ∞ ∞ ∞ ∞
B 6 ∼ 20 – 4 ∼ 12 4 ∼ 12 4 ∼ 12
C 4 ∼ 12 ∞ – ∞ ∞
(–)*
D 4 ∼ 12 ∞ ∞ – ∞
E 4 ∼ 12 ∞ ∞ ∞ –
(−)*: Tester (−) Lead Connection
• Install the regulator/rectifier (see Regulator/Rectifier In-

stallation).
Charging System
Charging System Troubleshooting
NOTE
Charging System
Capacitor Removal
• Disconnect the connector [A].
• Remove the bolts [B].
• Remove the capacitor [C] from the bracket.
Capacitor Installation
•○Installation is the reverse of removal.
Run the lead correctly (see Cable, Wire, and Hose Rout-
Capacitor Inspection
• Remove:
Capacitor (see Capacitor Removal)
• to thetheleads
Set hand tester to the × 1 kΩ range, connect the tester
of the capacitor, and check the internal resis-
tance the following table.
Special Tool - Hand Tester: 57001-1394
NOTICE
Use only Kawasaki Hand Tester 57001-1394 for this
test. A tester other than the Kawasaki Hand Tester
may show different readings.
If the readings do not correspond to the table, replace the
capacitor unit.
Capacitor Internal Resistance
Tester Positive (+) Lead Connection
Color O BK/W
Tester more than 5 kΩ
O —
Negative *1
(–) Lead Should not be
Connection inspected
BK/W —
*2
*1: Check the capacitor after 2 minutes.
*2: Do not check the resistance because of opposite of
the polarity.
Capacitor Capacity
10 000 F/50 V
Ignition Timing
Ignition Timing Inspection
• Remove the timing inspection cap [A].
• Attach the timing light [A] to the ignition coil lead in the
manner prescribed by the manufacturer.
Special Tool - Timing Light: 57001-1241
• Start the engine and aim the timing light at the TDC mark
[B] on the flywheel.
• Run the engine at the speeds specified and note the align-
ment of the TDC mark.
○Check the engine speed, using the engine revolution

tester [A] for high accuracy.
Ignition Timing
Engine speed [r/min (rpm)] Hole groove aligns with:
2 000 Line mark on flywheel
If the ignition timing is incorrect, check the crankshaft sen-
sor (see Crankshaft Sensor Inspection).
If the crankshaft sensor is normal, replace the ECU.
• Replace the timing inspection cap O-ring with a new one,
and apply grease it.
• Tighten:
Torque - Timing Inspection Cap: 3.5 N·m (0.36 kgf·m, 31
in·lb)
Ignition System
Safety Instructions
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plug, ignition coil or ig-
nition coil lead while the engine is running, or you
could receive a severe electrical shock.
Ignition Coil Removal

• Disconnect the primary lead connector [A].
• Remove the ignition
Pull off the spark plug cap [B].
• with bracket. coil bracket bolt [C] and ignition coil
• Remove the mounting bolts and nuts [A], and separate

the ignition coil [B] and its bracket [C].
Ignition Coil Installation

• Assemble the ignition coil and its bracket, and tighten the
bolts and nuts.
• Install the spark plug cap [A].
Front Side [B]
○Insert the spark plug cap to the cylinder head cover until
the flange of the cap contacts the cover.
• Run the leads correctly (see Cable, Wire, and Hose Rout-
• Install:
Ignition Coil [A] with Bracket
Frame Ground Lead (Inside) and Ignition Coil Ground
Lead (Outside) [B]
Ignition Coil Bracket Bolt
○Turn the clamp side of the ignition coil ground lead termi-
nal and frame ground lead terminal outside.
•Connect the primary lead connector.
•Pull up the spark plug cap lightly to make sure of the in-
stallation of the spark plug cap.
Ignition System
Ignition Coil Inspection
Measuring Arcing Distance
The most accurate test for determining the condition of
the ignition coil is made by measuring arcing distance using
the coil tester for the 3-needle method.
• Remove the ignition coil (see Ignition Coil Removal).
• Measure the arcing distance using the coil tester [A].
• Connect the ignition coil (with the spark plug cap left in-
stalled on the spark plug lead) [B] to the tester and mea-
sure the arcing distance.
WARNING
To avoid extremely high voltage shocks, do not
touch the coil or lead.
If the distance reading is less than the specified value, the
ignition coil or spark plug cap is defective.
3 Needle Arcing Distance
Standard: 7 mm (0.28 in.) or more
• To determine which part is defective, measure the arcing

distance again with the spark plug cap removed from the
spark plug lead.
If the arcing distance is subnormal as before, the trouble
is with the ignition coil itself. If the arcing distance is now
normal, the trouble is with the spark plug cap.
Measuring Coil Resistance
If the arcing tester is not available, the coil can be checked
for a broken or badly shorted winding with a digital meter.
However, the digital meter cannot detect layer shorts and
shorts resulting from insulation breakdown under high volt-
age.
• Remove the ignition coil (see Ignition Coil Removal).
• Measure the primary winding resistance [A] as follows.
○Connect the digital meter between the coil terminals.
• Measure the secondary winding resistance [B] as follows.
○Remove the spark plug cap from the spark plug lead.
○Connect the digital meter between the spark plug lead
and the ground lead terminal.
Ignition Coil Winding Resistance
Primary Windings: 0.28 ∼ 0.38 Ω at 20°C (68°F)
Secondary Windings: 7.65 ∼ 10.4 kΩ at 20°C (68°F)
If the digital meter does not read as specified, replace the
ignition coil.
If the digital meter reads as specified, the ignition coil
windings are probably good. However, if the ignition sys-
tem still does not perform as it should after all other com-
ponents have been checked, test replace the coil with one
known to be good.
• Check the spark plug lead for visible damage.
If the spark plug lead is damaged, replace the ignition coil.
Ignition System
Spark Plug Cleaning and Inspection
• Refer to the Spark Plug Cleaning and Inspection in the
Spark Plug Gap Inspection
• Refer to the Spark Plug Cleaning and Inspection in the
Ignition Coil Primary Peak Voltage Check
• Remove the spark plug cap from the spark plug, but do
not remove the spark plug.
• Install the good spark plug [A] to the spark plug cap, then
touch the frame with it.
NOTE
○Measure the voltage with each lead connected cor-
rectly. The correct value may not be obtained if
disconnected.
○Maintain the correct value of compression pressure for
the cylinder (Be sure to measure the voltage with the
spark plug installed to the cylinder head.).
• Connect the peak voltage adapter [B] to the tester.

Special Tools - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Needle Adapter Set: 57001-1457
• Connect the peak voltage adapter to the ignition coil ter-
minal and ground.
Connections:
Peak Voltage Tester
Adapter
Ground [C] ← R lead → (+)
Terminal (O
← BK lead → (–)
Lead) [D]
Ignition Coil [E]
ECU [F]
Needle Adapter [G]
• Shift the gear to the neutral position.

• Crank the engine by kicking the pedal several times to
measure the peak voltage of the ignition coil.
Ignition Coil Primary Peak Voltage
Standard: DC 150 V or more
WARNING
Electrical equipment can cause serious electrical
shock. To avoid being shocked, do not touch the
metal portion of the probe when measuring voltage.
If the voltage is less than the specified value, see the
Troubleshooting on next page.
Ignition System
IC Igniter Inspection
○The IC igniter is built in the ECU.
• Refer to the following items.
Ignition System Troubleshooting (see Ignition System
section)
ECU Power Supply Inspection (see ECU Power Supply
Inspection in the Fuel System (DFI) chapter)
Ignition System
Ignition System
Crankshaft Sensor Peak Voltage Check
• Disconnect the magneto lead connector (see Magneto
Cover Removal).
NOTE
○Measure the voltage with each lead connected cor-
rectly. The correct value may not be obtained if
disconnected.
○Maintain the correct value of compression pressure for
the cylinder (Be sure to measure the voltage with the
spark plug installed to the cylinder head.).
WARNING
Electrical equipment can cause serious electrical
shock. To avoid being shocked, do not touch the
metal portion of the probe when measuring voltage.
• Set a digital meter, and connect it to the peak voltage

adapter [A].
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
• Connect the adapter to the terminals of the magneto lead
connector [B].
Connections:
Magneto Lead Peak Voltage
Digital Meter
Connector Adapter
G/W lead [C] ← R lead → (+)
W/Y lead [D] ← BK lead → (–)
• Shift the gear to the neutral position.

• measurethetheengine
Crank by kicking the pedal several times to
peak voltage of the crankshaft sensor.
Crankshaft Sensor Peak Voltage
Standard: DC 2.5 V or more
If the voltage is less than the specified, check the crank-
shaft sensor (see Crankshaft Sensor Inspection).
Crankshaft Sensor Inspection
• Disconnect the magneto lead connector (see Magneto
Cover Removal).
• Set a digital meter [A] and connect it to the Green/White
[B] and White/Yellow [C] leads in the connector.
Crankshaft Sensor Resistance
Standard: 180 ∼ 280 Ω at 20°C (68°F)
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
• Using the digital meter, measure the resistance between
the crankshaft sensor leads and chassis ground.
Any digital meter reading less than infinity (∞) indicates a
short, necessities replacement of the crankshaft sensor
assembly.
Ignition System
Engine Stop Switch System Check
• Push the engine stop switch [A], stop the engine.
If the engine does not stop, check the engine stop switch
for continuity (see Engine Stop Switch Inspection).
If the engine stop switch is good, check the wiring (see
Wiring Inspection).
If the wiring is good, replace the ECU.
Launch Control Mode Button System Check

(KX250ZE ∼)
• Push thegear
Shift the to the neutral, 1st or 2nd position.
• two seconds. control mode button [A] for more than
launch
○The orange launch control mode indicator light (LED) [B]

will blink to indicate the system is operating.
•Apply the clutch lever and shift the gear to the 3rd position
to deactivate the system.
○The orange launch control mode indicator light (LED)
should stop blinking.
If the launch control mode system does not work as
above, check the following items.
Launch Control Mode Button (see Launch Control Mode
Button Inspection)
Orange Launch Control Mode Indicator Light (LED) (see
Orange FI Warning Indicator Light (LED) Inspection in
the Fuel System (DFI) chapter)
Wiring (see Wiring Inspection)
If the all parts are good condition, replace the ECU.
DFI Setting Data Selection Connector Inspection
White Connector [A] (for Soft Track Condition)
Green Connector [B] (for Standard)
Black Connector [C] (for Hard Track Condition)
Ignition System
• Check the wiring for continuity between the terminals of

each connector referring the connector circuit.
White Connector [A]
Green Connector [B]
Black Connector [C]
Digital Meter [D]
If a digital meter does not read 0 Ω, the connector is de-
fective. Replace the connector with a new one.
Switches
Engine Stop Switch Inspection
• Using a digital meter, check to see that the connections
shown in the table have continuity (about zero ohms).
If the switch has an open or short, replace it with a new
one.
Engine Stop Switch Connection
Launch Control Mode Button Inspection (KX250ZE

∼)
• Using a digital meter, check to see that the connections
shown in the table have continuity (about zero ohms).
If the switch has an open or short, replace it with a new
one.
Launch Control Mode Button Connection
Gear Position Switch Removal

• Refer to the Gear Position Switch Removal in the Fuel
System (DFI) chapter.
Gear Position Switch Installation
• Refer to the Gear Position Switch Installation in the Fuel
Gear Position Switch Inspection
• Refer to the Gear Position Switch Inspection in the Fuel
APPENDIX 17-1
Appendix
Table of Contents
Cable, Wire, and Hose Routing .............................................................................................. 17-2
Troubleshooting Guide ........................................................................................................... 17-15
17
17-2 APPENDIX
Cable, Wire, and Hose Routing
KX250ZD
1. Front Brake Hose

2. Run the throttle cables inside of the number plate.
3. Throttle Cable (Accelerator)
4. Throttle Cable (Decelerator)
5. Clutch Cable
6. Run the clutch cable inside of the number plate.
7. Run the front brake hose outside of the number plate.
8. Band (Hold the engine stop switch lead.)
9. Engine Stop Switch Lead
10. Run the engine stop switch lead and clutch cable into the guide.
11. Run the throttle cables into the guide.
APPENDIX 17-3
KX250ZE ∼
1. Front Brake Hose

2. Run the throttle cables inside of the number plate.
3. Throttle Cable (Accelerator)
4. Throttle Cable (Decelerator)
5. Clutch Cable
6. Run the clutch cable inside of the number plate.
7. Run the front brake hose outside of the number plate.
8. Band (Hold the engine stop switch lead and launch control mode button lead.)
9. Launch Control Mode Button
10. Engine Stop Switch
11. Run the engine stop switch lead, launch control mode button lead and clutch cable into the
guide.
12. Run the throttle cables into the guide.
17-4 APPENDIX
1. FI Warning Indicator Light Harness Connector (KX250ZD)

Launch Control Mode Button Lead Connector (KX250ZE ∼)
2. Run the launch control mode button lead outside of the clutch cable (KX250ZF).
3. Clutch Cable
5. Main Harness
6. Run the clutch cable outside of the main harness.
7. Clamps (Firmly twist the clamp from near bolted point around the clutch cable.)
8. Throttle Cables
9. Run the throttle cables between the joint hose and radiator overflow hose.
10. Run the regulator/rectifier lead as shown.
11. Put the regulator/rectifier lead connector on the top position.
12. Run the throttle cables over the main harness.
APPENDIX 17-5

2. Clamp (Hold the main harness and engine stop switch lead on the main harness at the white
taped position.)
3. Position the engine stop switch lead connector behind the clamp and between the main harness
and frame.
4. Run the capacitor lead to the right side of the capacitor.
5. Joint Hose
6. Main Harness
7. FI Warning Indicator Light Harness Connector (KX250ZD)
Launch Control Mode Button Lead Connector (KX250ZE ∼)
17-6 APPENDIX
1. Clamp (Turn the lock position to upward.)

2. Clamp (Turn the lock position to upward.)
3. Run the main harness and option lead over the capacitor lead.
4. Run the regulator/rectifier lead as shown.
5. Run the regulator/rectifier lead on the top position in the clamp.
6. Run the ignition coil primary lead outside of the clamp.
APPENDIX 17-7
17-8 APPENDIX
APPENDIX 17-9
1. Breather Hose
2. Downstream Lead
3. Throttle Sensor Lead
4. Install the upstream injector connector boot so that notch side faces inside.
5. Run the downstream lead and throttle sensor lead over the throttle body assy rear side.
6. Fuel Hose
7. Check the fuel hose position. If the fuel hose interferes with the cylinder head cover, move the
fuel hose upward.
8. Run the fuel pump lead over the fuel hose.
9. Run the throttle sensor lead to the front side of the throttle body assy.
10. Clamp (Hold the main harness. Turn the lock position to backward.)
17-10 APPENDIX
1. Clamp (Twist the clamp on the magneto lead and gear position switch lead at the gray taped
position.)
2. Clamp (Twist the clamp on the magneto lead and gear position switch lead.)
3. Run the gear position switch lead inside of the gasket.
4. Do not pinch the gear position switch lead.
5. Insert the gear position switch lead into the groove of the crankcase.
APPENDIX 17-11
1. Viewed Rear 9. Capacitor (Position the lead downward.)

2. Radiator Overflow Hose 10. Run the radiator overflow hose in the left
3. Clamps of the frame pipe, and in the front of the
4. Joint Hose (Turn the blue paint to upside.) water hose.
5. Clamps (Turn the screw head to outside.) 11. Left Radiator
6. Right Radiator 12. Viewed A
7. Water Pipe 13. 45°
8. Run the radiator overflow hose in the front 14. Viewed B
of the water hose and between the engine 15. Bottom Engine Guard
brackets.
17-12 APPENDIX
1. Install the mesh protector side of the 9. Clamps (Turn the screw head to exhaust
breather hose to the engine. pipe side.)
2. Clamp (Turn the claw to the exhaust pipe 10. Joint Pipe
side.) 11. Clamp (Turn the screw head to outside.)
3. Clamp (Run the breather hose into the 12. Turn the green paint to outside.
clamp.) 13. Viewed A
4. Breather Hose 14. Insert the water hose to the pipe up to the
5. Align the green paint to the stopper. clamp screw.
6. Stoppers 15. Clamp (Turn the screw head to front.)
7. Align the red paint to the stopper. 16. Turn the green paint to front.
8. Clamps (Turn the screw head to front.) 17. Water Pipe
APPENDIX 17-13
1. Touch the front brake hose fitting to the stopper.

2. Brake Hose
3. Clamp
4. Viewed A
5. Clamps
17-14 APPENDIX
1. Brake Hose
2. Clamps
3. Touch the rear brake hose fitting to the stopper.
4. Cotter Pin
5. Viewed A
APPENDIX 17-15
Troubleshooting Guide
NOTE Valve spring broken or weak
○Refer to the Fuel System (DFI) chapter for Valve not seating properly (valve bent, de-
most of DFI trouble shooting guide. formed, worn, or carbon accumulation on
○This is not an exhaustive list, giving every the seating surface)
possible cause for each problem listed. It Decompression trouble
is meant simply as a rough guide to assist
the troubleshooting for some of the more Poor Running at Low Speed:
common difficulties. Spark weak:
Engine Doesn’t Start, Starting Spark plug dirty, broken, or gap malad-
Difficulty: justed
Engine won’t turn over: Spark plug cap or spark plug lead trouble
Valve seizure Spark plug cap shorted or not in good con-
Valve lifter seizure tact
Cylinder, piston seizure Spark plug incorrect heat value
Crankshaft seizure ECU trouble
Connecting rod small end, big end seizure Crankshaft sensor trouble
Transmission gear or bearing seizure Flywheel damaged
Camshaft seizure Ignition coil trouble
Kick shaft return spring broken Wiring connector not in good contact
Kick ratchet gear not engaging Fuel/air mixture incorrect:
No fuel flow: Air cleaner clogged, poorly sealed, or miss-
No fuel in fuel tank ing
Fuel tank cap air vent obstructed Fuel tank air vent obstructed
Fuel line clogged Fuel pump trouble
Fuel filter clogged Throttle body assy holder loose
Engine flooded: Air cleaner duct loose
Clean spark plug and adjust plug gap Compression low:
Starting technique faulty Spark plug loose
(When flooded, do not crank the engine with Cylinder head not sufficiently tightened
the throttle fully opened. This promotes down
engine flood because more fuel is supplied No valve clearance
automatically by DFI.) Cylinder, piston worn
No spark; spark weak: Piston ring bad (worn, weak, broken, or
Spark plug dirty, broken, or gap malad- sticking)
justed Piston ring/groove clearance excessive
Spark plug cap or spark plug lead trouble Cylinder head gasket damaged
Spark plug cap shorted or not in good con- Cylinder head warped
tact Valve spring broken or weak
Spark plug incorrect heat value Valve not seating properly (valve bent, de-
ECU trouble formed, worn, or carbon accumulation on
Crankshaft sensor trouble the seating surface)
Ignition coil trouble Decompression trouble
Engine stop switch shorted Other:
Wiring shorted or open ECU trouble
Flywheel damage Engine oil level to high
Compression Low: Engine oil viscosity too high
Spark plug loose Brake dragging
Cylinder head not sufficiently tightened Drive train trouble
down Engine overheating
No valve clearance Clutch slipping
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or Poor Running or No Power at High
sticking) Speed:
Piston ring/groove clearance excessive Firing incorrect:
Cylinder head gasket damaged Spark plug dirty, broken, or gap malad-
Cylinder head warped justed
Spark plug cap or spark plug lead trouble
17-16 APPENDIX
Spark plug cap shorted or not in good con- Fuel/air mixture incorrect:
tact Throttle body assy holder loose
Spark plug incorrect heat value Air cleaner duct loose
ECU trouble Air cleaner poorly sealed, or missing
Crankshaft sensor trouble Air cleaner clogged
Flywheel damage Compression high:
Ignition coil trouble Carbon built up in combustion chamber
Wiring connector not in good contact Engine load faulty:
Fuel/air mixture incorrect: Clutch slipping
Air cleaner clogged, poorly sealed, or miss- Engine oil level too high
ing Engine oil viscosity too high
Air cleaner duct loose Brake dragging
Water or foreign matter in fuel Drive train trouble
Throttle body assy holder loose Lubrication inadequate:
Fuel to injector insufficient Engine oil level too low
Fuel tank air vent obstructed Engine oil poor quality or incorrect
Fuel line clogged Coolant incorrect:
Fuel pump trouble Coolant level too low
Compression low: Coolant deteriorated
Spark plug loose Cooling system component incorrect:
Cylinder head not sufficiently tightened Radiator clogged
down Radiator cap trouble
No valve clearance Water pump not rotating
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or Clutch Operation Faulty:
sticking) Clutch slipping:
Piston ring/groove clearance excessive No clutch lever play
Cylinder head gasket damaged Clutch cable maladjusted
Cylinder head warped Clutch inner cable sticking
Valve spring broken or weak Friction plate worn or warped
Valve not seating properly (valve bent, de- Steel plate worn or warped
formed, worn, carbon accumulation on Clutch spring broken or weak
the seating surface.) Clutch release function trouble
Decompression trouble Clutch hub or housing unevenly worn
Knocking: Clutch not disengaging properly:
Carbon built up in combustion chamber Clutch lever play excessive
Fuel poor quality or incorrect Clutch spring compression uneven
Spark plug incorrect heat valve Engine oil deteriorated
ECU trouble Engine oil viscosity too high
Other: Engine oil level too high
Throttle valve won’t fully open Clutch housing seized
Brake dragging Clutch release function trouble
Air cleaner clogged Clutch hub nut loose
Water or foreign matter in fuel Clutch plate warped or rough
Clutch slipping Clutch hub spline damaged
Overheating
Engine oil level too high Gear Shifting Faulty:
Engine oil viscosity too high Doesn’t go into gear; shift pedal doesn’t
Drive train trouble return:
Crankshaft bearing worn or damage Clutch not disengaging
Shift fork bent, worn, or seized
Engine Overheating: Shift return spring pin loose
Firing incorrect: Shift return spring weak or broken
Spark plug dirty, broken, or maladjusted Shift shaft lever broken
Spark plug incorrect Pawl guide plate broken
ECU trouble Shift pawl broken
Shift pawl spring tension lose
APPENDIX 17-17
Gear seized Clutch housing gear worn
Gear positioning lever operation trouble Metal chips jammed in clutch housing gear
Shift drum broken teeth
Jumps out of gear: Transmission noise:
Shift fork ear worn, bent Bearings worn
Gear groove worn Transmission gears worn or chipped
Gear dogs and/or dog holes worn Metal chips jammed in gear teeth
Shift drum groove worn Engine oil insufficient, low viscosity
Gear positioning lever spring weak or bro- Kick ratchet gear not properly disengaging
ken from kick gear
Shift fork guide pin worn Kick shaft idle gear worn or chipped
Drive shaft, output shaft, and/or gear Drive chain noise:
splines worn Drive chain maladjusted
Overshifts: Drive chain worn
Gear positioning lever spring weak or bro- Rear and/or engine sprocket worn
ken Drive chain lubrication insufficient
Pawl guide plate worn Rear wheel misaligned
Abnormal Engine Noise: Abnormal Frame Noise:

Knocking: Front fork noise:
ECU trouble Oil insufficient or too thin
Carbon built up in combustion chamber Spring weak or broken
Fuel poor quality or incorrect Front fork air pressure high
Spark plug incorrect heat value Rear shock absorber noise:
Overheating Shock absorber trouble
Piston slap: Spring weak or broken
Cylinder/piston clearance excessive Disc brake noise:
Cylinder, piston worn Pad surface glazed
Connecting rod bent Disc warped
Piston pin, piston pin hole worn Caliper trouble
Valve noise: Pad installed incorrectly
Valve clearance incorrect Master cylinder damaged
Valve spring broken or weak Other noise:
Camshaft bearing or cam face worn Bracket, nut, bolt, etc., not properly
Valve lifter worn mounted or tightened
Other noise:
Connecting rod big end, small end clear- Abnormal Exhaust Color:
ance excessive White smoke:
Piston ring worn, broken, or stuck Piston oil ring worn
Piston seizure, damage Cylinder worn
Cylinder head gasket leaking Valve oil seal damaged
Exhaust pipe leaking at cylinder head con- Valve guide worn
nection Engine oil level too high
Crankshaft runout excessive Black smoke:
Engine mounts loose Air cleaner element clogged
Crankshaft bearing worn Brown smoke:
Camshaft chain tensioner trouble Air cleaner duct loose
Camshaft chain, sprocket, chain guide worn Air cleaner clogged
Primary gear worn or damaged Air cleaner poorly sealed or missing
Decompressor spring broken
Magneto flywheel loose Handling and/or Stability
Unsatisfactory:
Abnormal Drive Train Noise: Handlebars hard to turn:
Clutch noise: Cable, hose, wire routing incorrect
Clutch housing finger and friction plate tang Steering stem nut too tight
worn Steering stem bearing damaged
17-18 APPENDIX
Steering stem bearing lubrication inade- Front fork oil excessive
quate Front fork oil viscosity too high
Steering stem bent Rear shock absorber adjustment too hard
Tire air pressure too low Front fork bent
Handlebars shakes or excessively Front fork air pressure too high
vibrates: (Too soft)
Tire worn Front fork oil insufficient or leaking
Swingarm pivot bearings worn Front fork oil viscosity too low
Rim warped, or not balanced Rear shock absorber adjusted too soft
Spokes loose Front fork, rear shock absorber spring weak
Wheel bearing worn Rear shock absorber oil or gas leaking
Handlebar clamp bolt loose Tire air pressure too low
Steering stem head nut loose
Front, rear axle runout excessive Brake Doesn’t Hold:
Handlebars pulls to one side: Air in brake system
Frame bent Pad, disc worn
Rear wheel misalignment Brake fluid leakage
Swingarm bent or twisted Contaminated pad
Swingarm pivot shaft bent Brake fluid deteriorated
Steering maladjusted Brake master cylinder cups damaged
Steering stem bent Master cylinder scratched inside
Front fork bent Disc warped
Suspension operation trouble:
(Too hard)
Tire air pressure too high
Part No.99924-1459-03
MODEL APPLICATION
Year Model Beginning Frame No.
JKAKXMZC□DA000001
2013 KX250ZD
JKAKX250ZZA000001
JKAKXMZC□EA013001
2014 KX250ZE
JKAKX250ZZA013001
JKAKXMZC□FA025001
2015 KX250ZF
JKAKX250ZZA025001
□:This digit in the frame number changes from one machine to another.

KX250F (2013-2015)

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KX250F

Quick Reference Guide

This quick reference guide will assist

COUNTRY AND AREA CODES

Cleaning Vehicle before Disassembly

Arrangement and Cleaning of Removed Parts

Liquid Gasket, Non-permanent Locking Agent

Oil Seal, Grease Seal

Apply specified grease to the lip of seal before installing

Circlips, Cotter Pins

KX250ZD Right Side View

Frame Number Engine Number

Units of Volume: Units of Pressure:

Units of Force: Units of Power:

Rear Sprocket Warp (Runout) Inspection ......................................................................... 2-39

FREQUENCY Each Every Every 6

Basic Torque for General Fasteners

Item Standard Service Limit

Item Standard Service Limit

Item Standard Service Limit

Steering Stem Nut Wrench: Fork Spring Compressor:

Jack: Jack Attachment:

Fork Oil Level Gauge: Top Plug Wrench, 36 mm:

• Screw the throttle cable adjuster [B] to give the throttle

If the throttle grip free play cannot be adjusted with the

Fuel Hose Replacement

Throttle Body Assy Side

When removing with fingers:

• Clean the delivery pipe.

When removing with fingers:

• Clean the delivery pipe.

• Remove the vinyl bag on each delivery pipe.

• Apply engine oil to the fuel outlet pipe [A] lightly.

Idle Speed Inspection

• Start the engine and warm it up thoroughly.

If handlebars movement changes the idle speed, the

• Check the idle speed, using the engine revolution tester

Idle Speed Adjustment

Air Cleaner Element Cleaning and Inspection

• Separate the element [A] from the frame [B].

• Clean the element [A] in a bath of a high flash-point sol-

• Squeeze it dry in a clean towel [A]. Do not wring the ele-

• After cleaning, saturate the element with a high-quality

• Apply grease to all connections and screw holes in the air

Fuel Tank Cleaning

• Remove the right radiator shroud (see Radiator Shroud

• Check the coolant level. The coolant level [A] should be

Engine Top End

• Bring the piston to the TDC of the compression stroke to

• Using a thickness gauge [A], measure the clearance be-

• Clean the shim to remove any dust or oil.

•○Install the shim.

• Remove the valves (see Valve Removal in the Engine Top

Cylinder Wear Inspection

• Visually inspect the inside of the cylinder for scratches

• Take a side-to-side and a front-to-back measurement as

Cylinder Inside Diameter

Piston, Piston Ring and Piston Pin Replacement

•○Remove the muffler cover [A].

• Using a high flash-point solvent, clean off any oil or dirt