2009 kx250f service manual

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Join the Cyclepedia Reseller network by becoming an online affiliate. Rear Reservoir A. Front Reservoir B. Minimum Level Line B. Page 82 front or rear brake caliper is less than 1 mm 0. Pad replacement should be done by an authorized Kawasaki dealer. Lining Thickness B. Kawasaki dealer. Since the air pressure in the fork legs increases with normal use, the fork action on your KX will get stiffer as the race progresses. Depending on the model, the fork com- The standard air pressure in the front fork legs is pression damping adjuster has at least 22 positions.

Adjust the compression damping to suit your preference under certain con- ditions. Adjust the rebound damping to suit your preference under certain conditions. Loosen the front fork cylinder unit with the top plug wrench special tool. Do not take off the base valve assembly. Loosen the right front axle clamp bolts. Pull down by twisting. Measure the length A. Top Plug Wrench P. Fork Oil A. Fork Cylinder Unit B. Axle Holder Bottom C.

Locknut A. Push Rod B. Adjuster Assembly the top plug wrench special tool. Cylinder Unit A. Fork Spring B. Base Valve Assembly C. Piston Rod C. Base Valve Assembly A. Fork Oil B. Slowly compress the piston rod until it stops so that the base valve assembly can be removed easily.

Fork oil B. Oil Holes C. Fork Cylinder Unit A. Threads D. Pump the Piston. Piston Rod B. O-rings A. Base Valve Assembly B. Ser- vice carefully because oil flies out from the oil hole of the cylinder unit. Do not place the fingers etc. Outer Tube C. Push Rod A. Adjuster Assembly B. More Than 1 mm 0. Axle Holder Part B. Wrench B. Adjuster Assembly C.

Torque Wrench D. Outer Tube B. Fork Oil C. Be sure the oil capacity is the same in both fork legs. Standard Oil ml Quantity Standard Oil Rebound Damping Adjuster If the damping feels too soft or too stiff, adjust it in A. Softer Counterclockwise C. Harder Clockwise D. NOTE Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the com- pression damping force. Spring Preload Adjusting Nut A. Hook Wrench P. Locknut B. Spring Preload Adjusting Nut C. Hook Wrenches P.

Page Always wear eye and face protection when working on the rear shock absorber. Removal and installation of the rear shock absorber spring should be performed by an authorized Kawasaki dealer. Adjusting Nut Position B. Locknut C. Spring Preload Adjusting Nut Mishandling can cause explosion. Tire air pressure affects traction, handling, and tire Do not incinerate, puncture or open.

Unevenly tightened or loose spokes will cause the rim to warp, the nipples and spokes to fatigue more quickly, and the spokes to break. Disregard this when measuring rim runout. Rim Runout A. Axial Rim Runout Measurement A. Rim B. Radial Runout C. Check also that all cotter pins are in place and in good condition. Silencer Pipe Mounting Uni-Trak Arm Bolt Kick Pedal Pivot Bolt Silencer Cover Mounting Rear Axle Nut An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider.

Covering hose to remove any loose dirt. Af- ter drying, apply a corrosion protection spray on all Chrome and uncoated aluminum parts can be metal and chrome surfaces to prevent corrosion. Coated aluminum should be washed with a mild neutral de- Painted Surfaces A heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. Radial 1.

Tires Air Pressure Front and Rear This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. Place blocks under the wheel so that the disc does not touch the ground. Engine Sprocket 4. Output Shaft 5. Chain Slipper 6. Swingarm 7. Chain Guide 8. Locknut 9. Adjusting Bolt Chain Adjuster Chain Slack — — — Chain link Length mm Never reuse old brake fluid.

Do not use fluid from a container that has been left unsealed or that has been open for a long time. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air.

Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. There will be a gap at the lower part of the clamp after tightening.

If it is scratched or damaged, replace the disc. Replace the disc if it has worn past the service limit. Thickness Standard: 2. Air pressure in the fork legs increase with normal use, so the fork action stiffens during opera- tion. Release air pressure form the fork legs prior to each race through the pressure relief screw located in each cap of the base valve assembly.

The piston rod may slide into the inner tube. If oil leaks from the base valve assembly part or bottom of the cylinder. Do not place the fingers etc.

Replace it if necessary. It consists of a rear shock absorber, swing arm, tie-rod and rocker arm. 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.

If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. Seated position: adjuster turned fully clockwise [A]. Special Tools - Hook Wrench R Re- moval may damage them. If the sleeve is worn past the service limit, replace the sleeve. Pad Cover with Pad 7. L: Apply a non-permanent locking agent. R: Replacement Parts Learn and ob- serve all the rules below.

Such a shock to the parts can damage them. If any wiring is poor, replace the damaged wiring. If the connector is corroded or dirty, clean it carefully. Page Flywheel Magneto Be sure to install the dowel pins [A].

Do not touch the stick coil while the engine is running, or you could receive a severe electrical shock. Unit in- spection. Throttle Cables 6. Clutch Cable 2.

Marked AAA cable is accelerator side. Clamp Run the clutch and hot start ca- 3. Band Hold the engine stop switch lead. Engine Stop Switch Lead 8. Clutch Cable Engine Stop Switch Lead Connector 2. Engine Stop Switch Lead Clamp Run the hot start cable and main 3. Unit harness. Main Harness Clamp Hold the hot start cable and throt- 5. Unit Fuel Hose 2. Hot Start Cable 3. Clamp Run the hot start cable and main Throttle Sensor Lead harness. Install the clamp direction as shown in the 4.

Clumps Position the clamp claw front. Water Pipe 2. Install the upper radiator tube so that the 8. Install the screw head of the clamps di- yellow painted mark faces upward. Run the fuel hose inside the hot start cable. Align the end of the net protector with the cam chain tensioner cap. Breather Tube 4. Align the white painted mark of the tube with the rib of the crankcase.

Brake Lever Rear Brake Master Cylinder 2. Front Brake Master Cylinder Rear Brake Hose 3. Front Brake Hose Clamps 4. Clamp Rear Brake Caliper 5. Viewed Rear Brake Caliper Guard 6.

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