1987-2004 Kawasaki KSF250 Mojave 250 ATV Service & Repair Manual

KSF250 Kawasaki MOJAVE All Terrain Vehicle Service Manual

This quick reference guide will assist you in locating a desired topic or procedure. • Bend the pages back to match the black tab of the desired chapter number 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 specific topic required. Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation CrankshaftlTransmission WheelslTires Final Drive Brakes Suspension Steering Frame Electrical System Appendix Supplement - 1988 ,..., 1989 Models Supplement - 1990 ,..., 1997 Models Supplement - 2000 ,..., 2002 Models Supplement - 2003 ,..., 2004 Models

Kawasaki KSF250 MOJAVE Motorcycle Service Manual Fourteenth Edition (1) : Apr. 10, 2003 (K)

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level. A ABOC AC ATDC BBDC BOC BTDC °C DC F of ft g h L WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow safety instructions This warning may apply to any of the following components or any assembly containing one or more of these components:- Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS eOperate if possible out of doors or in a well ventilated place. ePreferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped. elf possible, dampen before cutting or drilling. eDam pen dust and place it in properly closed receptacle and dispose of it safely. LIST OF ABBREVIATIONS ampere(s) Ib pound(s) after bottom dead center m meter(s) alternating current min minute(s) after top dead center N newton (5) before bottom dead center Pa pascal (s) bottom dead center PS horsepower before top dead center psi pound (s) per square inch degree(s) Celsius r revolution direct current rpm revolution (5) per minute farad(s) TOe top dead center degree(s) Fahrenheit TIR total indicator reading foot, feet V volt(s) gram(s) W watt(s) hour(s) n ohm{s) liter(s) I Read OJVNER'S MANUAL before operating. I

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tool'S may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: - Follow the Periodic Maintenance Chart in the Service Manual. -Be alert for problems and non-scheduled maintenance. -Use proper tools and genuine Kawasaki vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. -Follow the procedures in this manual carefully. Don't take shortcuts. - Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructionsl Always follow safe operating and maintenance practices. I WARNING I o This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. o This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or des- truction of equipment. This manual contains five more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation.

elndicates a procedural step or work to be done. olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE. *Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. *Indicates a conditional sub-step or what action to take based upon the results of the conditional step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL LUBRICATION 1-1 General Information Table of Contents Before Servicing .......................................... . Model Identification ....................................... . General Specifications ..................................... . Periodic Maintenance Chart ................................. . Torque and Locking Agent .................................. . Cable and Harness Routing .................................. . 1-2 1-4 1-5 1-7 1-8 1-10

1~2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, 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: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Disconnect the ground (-) wire from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-turn before removing them. (5) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (6) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. (7) Edges Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over. (8) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (9) Gasket, a-Ring Replace a gasket or an a-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or a-ring to ensure a perfectly smooth surface to prevent oil or compression leaks. (10) Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage. (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12) Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component. (13) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer's marks, press it in with the marks facing out.

GENERAL INFORMATION 1-3 (14) Circlip, Retaining Ring, and Cotter Pin When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem. (15) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. (16) Direction of Engine Rotation To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well. (17) Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so deSignated in their respective text, they are replacement parts. (18) Electrical Wires All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stripe color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed. Unless instructed otherwise, electrical wires must be connected to wires of the same color. Two-Color Electrical Wire (cross-sect ion) Color Indicated on tne Wire Color Indicated on the Wiring Diagram Red Wire Strands Ye I low/Red ---Y/R--- Ye I low Red GB020601Wl C (19) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Bent Dent Scratch Color change Deterioration Seizure (20) Specifications Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have. Warp Wear "Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

1-4 GENERAL INFORMATION Model Identification KSF250-A 1 Left Side View: KSF250-A 1 Right Side View:

1987-2004 Kawasaki KSF250 Mojave 250 ATV Service & Repair Manual

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