1987-1988 Kawasaki KXF250 TECATE-4 OEM Service & Repair Manual

KXF250 Kawa ki CATE 4 All Terrain Vehic e Service Manual First Editi on CD: p r. 24, 1987 CD

This qu ick reference guide will assist you in locating a desired topic or procedure . eBend 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. eR e fer to the sectional table of contents for the exact pages to locate the specific top ic required . Quick Reference Guide General Information Fuel System Cooling System Engine Top End Engine Right Side Engine Left Side Engine Removal/Installation Cra nkshaft/Tra nsm ission Whe els/Tires Final Drive Brakes Suspension Steering Fra me Electrical System Appendix

... , ",.,. .. . • •• .' ••• • .... 1 :7r: · ... · .. ... · .. · . . . · . III. ........ - PLEASE 00 NO T TAMPER WITH NOISE CONTROL SY STEM To mi n im ize the noise emissions from this prod uct, Kawasaki has equipped it with effective intake and exhaust silencing sys te ms. They are designed to give op timum per- fo rma nce while maintaining a low noise level. Please do not remove these systems , or alter the m in any which results in an increase in noise level. LI ST OF ABBREVIATI ONS A ampere(s) Ib pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal (s) BDC bottom dead center PS horsepower BT DC before top dead center psi pound(s) per square inch °C degree(s) Celcius r revolution DC direct current rpm revolution(s) per minute F farad(s) TD C top dead center OF degr ee(s) Fah ren heit TIR to tal indicator reading ft foot, feet V volt(s) g gram(s) W watt(s) h ho u r(s) n ohm(s) L liter(s) Read OWNER'S MANUAL before operating

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. Howeve r, 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 onlv by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yoursel~ 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 equ ipment. Precision measurements can only be made if the proper instruments ar e used, and the use of substitute too ls may adversely affect safe operation. For the duration of your warran ty period, especially, 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 wi th this manual may void the warranty. To get the longest life out of your veh ic le: eFoliow the Periodic Maintenance Chart in the Serv ice Manual. eBe alert for problems and non-scheduled maintenanc e. eUse proper tools and genuine Kawasaki vehicle parts. Special to ols, gauges, and testers that are necessary when serv icing Kawasa ki vehicles are introduced by the Special Tool Manual. Genuine parts provided as spare par ts are listed in th e Part s Catalog. e Follow the procedures in this manual carefully. Don 't take shortcuts. eRemember to keep complete records of ma in- ten ance and repair with dates and any new parts in stalle d. How to Use this Manual In preparing this manual, we divided the product into its major systems. These !i)'st,ems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. Th e 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 Ch art is located in the General Informati· on chapter. The chart gives a time schedule for requ ired maintenance operations. If you want spark plug infor mation, for exa mp le, go to the Periodic Ma intenance Chart first. The chart tells you how frequ ent ly to clean and ga p 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 pract ices. C WA RN ING ' oThis warning symbol i dentifies special instructions or procedures wh ich, if not correctly followed , co uld result in personal injury, or loss of life. o This caution symbol id ent ifies special instructions or procedures which, if not strictly ob- served, could result in damage to or des- tru ct ion of equipment. This manual contains five more symbo ls (in addition to WARN I NG and CAUT ION) which will help you distinguish different types of in format ion. NOTE o This note symbol indicates points of particular interest for more effi cient and convenient operation.

elndicates 8 procedural step or work to be done . o Indicates a procedural sub- step or how to do the work of the procedural step it fo ll ows. 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 wh at actio n to take based upon the resu lts of the conditional step it follows. In most chapters an exploded view ill us tr ation of the system components fo llo ws t he Ta bl e 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 INFORMATION 1-1 General Information Ta ble of Contents Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1·4 General Specifications ... .. ........... . ..................... 1-5 Cable and Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1·10 Periodic Maintenance Chart ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 12

1-2 GE NERAL INFOR MATION Before Servicing Before startin g to service a vehicle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, no,tes, cautions, warnings, and detailed des- cripti ons have been included wherever necessary. Nevertheless, even a detailed account has limi- tations, a certain amount of basic knowledge is also requir ed for successful work. Especially note the following: ( 1) Di rt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before install ing a new part, clean off any dust or meta l filings. (2) Tightening Sequence Generally, when installing a part with several bo lts, nuts, or screws, start them all in their holes and tig hten them to a snug fit. Then tighten them evenly a cross pattern. This is to avoid dis- t ortion of the p' art and/or causing gas or o, il 'leakage. Conversely when loosening the bolts, nuts, or screws, 1irst loosen all of them by about a qu art er of turn and then remove them. Where there is a tightening sequence Indication in this Service Manual, the bolts, nuts, or screws must be tight ened in the order and method indicated. (3.) Torque When to rque values are given in this Service Manual, use them. Either too little or too much torque many ll ead to serious damage. Use a good qual ity, reliable torque wrench. (4) Fo rce Common sense should dict at e how much force is necessary in assembly and disassembly. If a part seems e·specially dif f ic ult 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 removal of screws held by a locking agent) in order to avoid damaging the screw heads. (5) Edges Wa tch for sharp edges" especially during major engine disassembly and assembly. Protect your hands" with gloves or a piece of t bick cloth whe n lifting the engine or turning it over. (6) High-Flash Point So lvent A high-flash pOl int ,solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is St oddard solvent (generic name). Always follow manufacturer and container direct ions regarding the use of any solvent. (7) Gask et, O-Ring Do not reuse a gask et or O-ring once it has been in service. The mating surfaces around the gask et should be free of for e ign matt er and perfectly smooth to avoid oil or compression leaks. (8) Liquid Gasket, Non-Pe rmanent Locking Agent Fo llow manufac turer's directions for cleaning and preparing surfaces wher e these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious dam age. An ex ample of a non-permanent lOCki ng age nt commonly available in North America is L octite Lock'n Seal (Blue). (9) Press A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on i ts ou ter or inner circumference so that it will go into place smoothly. (10) Ball Beari ng When installing a ball bearing, t he bearing race whic h is affected by friction should be pushed by a suitable driver. Th is prev ent s severe stress on the balls and races, and preve nts races and balls from being dented. Press a ba ll bear ing until it stops at the stop in the hole or on the shaft. (11) Oil Seal and Grease Seal Replace an y oil or grease seals that were removed with new ones , as remo val gen erall y dam ages seals. When pressing in a seal which has manufacturer' s marks, press it in with the marks facing out. Seals should be pressed into place using a su itable d'river, which con tacts evenly with the side of seal, until the face of the seal is even wit h the end of the hole.

GENERAL INFORMATION 1-3 (12) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. (13) Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (14) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off . Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. 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. This manual makes reference to molybdenum disulfide grease (MoS 2 ) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. (15) Electrical Wires All the electrical wires are either single~Qlor or two - color and, with only a few exceptions, must be connected to wires of the same co'lor. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "y , ellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color. Wire (cross-section) Name of Wire Color ~~!d"":--r- Wire strands Yellow/red Yellow (16) Replacement Parts When there is a replacement instruction, rep lace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (17) Inspection When parts have been disassembled, visual1 ly inspect these parts f or the following con ditions or other damage. If there is any doubt as to tile condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Det erior ation Seizure (18) Specifications Specification term s are defined as follows. "Standards" show dimensi ons or p erformances which brand-new parts or systems have. "Service limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performan ce, rep lace the damaged parts .

1-4 GE NE RAL INFO RM ATION Model Identification KXF250-A1

Gen era l Spec ifi cations Items Dimensions: Overall length Overall width Overall height Wheelbase Grou nd clearance Seat height Dry weight Curb weight: Front Rear Fue l tank capacity Performan ce: Braking distance Minimum turning radius I KXF2 50 -A1 1 1.800 mm 1,130 mm 1,075 mm 1,225 mm 285mm 800mm 149 kg 80.5 kg 79.5 kg 9.0 L 3.2 m GENERAL INFORMATION 1-5 -- -------- ------+--- ----- ------ -------- -- -------- -- - Engine: ** Type Cooling System Bo re and stroke Displacement Co mpression ratio Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug P ort timing: Inlet Scavenging Exhaust Lubrication system Eng ine oil Op en Cl ose Open Cl ose Duration Open Close Duration 2-strok e, single cylinder **piston reed valve Liqu id-cooled 67.4 x 70.0 mm 249 mL 8.7 Carburetor, Mikuni VM34SS Primary kick CDI Electronically advanced 18° BTDC @6,000 r/min (rpm) NGK B8ES Full open 59.5 0 (BBDC) 59.5° (ABDC) 119 0 88.25° (B BDC) 88.25° (ABDe l 176.5° Petrol mix (20: 1) 2-stroke racing oil This engine licensed under one or more of Eyvind Boyessen's Patent Nos: 3,9 05 , 340.3,905,341. Re.30,425. 4,062,331. 4,161,163. 4,2 02 ,298 and 4,202/299.

1987-1988 Kawasaki KXF250 TECATE-4 OEM Service & Repair Manual

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