Kawasaki KX250F 2009 Owner's manual

Quick Reference Guide

GENERAL INFORMATION

j

MAINTENANCE AND ADJUSTMENT j

TROUBLESHOOTING GUIDE j

ENGINE AND SUSPENS

ION TUNING

j

STORAGE

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This Quick Reference Guide will assist you in

finding the in

formation you’re looking for.

A Table of Contents is included after the

Foreword.

IMPORTANT INFORMATION

•

This vehicle is designed for the operator only, no passengers.

•

This vehicle is a competition model only and was not manufactured for use on public streets, roads or

highways.

•

The use of this vehicle should be limited to participation in sanctioned competition events upon a closed

course.

•

This vehicle should not be used for general off-road recreational riding.

•

Read owner’s manual.

Whenever you see the symbols shown below,

heed their instructions! Always follow safe operat-

ing and maintenance practices.

WARNING

This warning symbol identifies special in-

structions or procedures which, if not cor-

rectly followed, could result in injury or

death.

CAUTION

This caution symbol identifies special in-

structions or procedures which, if not strictly

observed, could result in damage to or de-

struction of equipment.

NOTE

ż

This note symbol indicates points of particular in-

terest for more efficient and convenient operation.

IMPORTANT NOTICE

THIS VEHICLE IS A COMPETITION MODEL

ONLY AND WAS NOT MANUFACTURED

FOR, NOR SHOULD IT BE USED ON, PUB-

LIC STREETS, ROADS, OR HIGHWAYS. THE

USE OF THIS VEHICLE SHOULD BE LIMITED

TO PARTICIPATION IN SANCTIONED COMPE-

TITION EVENTS UPON A CLOSED COURSE.

THIS VEHICLE SHOULD NOT BE USED FOR

GENERAL OFF-ROAD RECREATIONAL RID-

ING.

READ OWNER’S MANUAL.

WARNING

THIS VEHICLE SHOULD NOT BE USED FOR

GENERAL OFF-ROAD RECREATIONAL RID-

ING.

DISCLAIMER OF WARRANTY

This motorcycle is sold AS IS, with all faults,

obvious or concealed and there are NO WAR-

RANTIES, expressed or implied. Including war-

ranties of MERCHANTABILITY or FITNESS FOR

PURPOSE.

The purchaser accepts all responsibilities con-

cerning quality, performance, cost of service

and/or necessary repairs.

Motorcycle Noise Emission Control

Information

This motorcycle is designed for closed course

competition use only. It does not conform to

U.S. EPA motorcycle noise standards.

NOTICE

Off-road motorcycling is a wonderful sport,

and we hope you will enjoy it to the fullest. How-

ever, if improperly conducted, this sport has the

potential to cause environmental problems as

well as conflicts with other people.

Responsible use of your off-road motorcycle

will ensure that these problems and conflicts do

not occur. TO PROTECT THE FUTURE OF YOUR

SPORT, MAKE SURE YOU USE YOUR MOTOR-

CYCLE LEGALLY, SHOW CONCERN FOR THE

ENVIRONMENT, AND RESPECT THE RIGHTS

OF OTHER PEOPLE.

FOREWORD

Congratulations on your choosing this Kawasaki motorcycle. Your new motorcycle is the product of

Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for a superior lightweight,

high-performance machine with superb handling and stability for racing and sporting use.

Your new KX is a highly tuned competition machine for participation in racing events. As with any mechan-

ical device, proper care and maintenance are important for trouble-free operation and top performance. This

manual is written to enable you to keep your KX properly tuned and adjusted.

Due to improvements in design and performance made during production, in some cases there may be minor discrepanc

ies between

the actual vehicle and the illustrations and text in this manual.

KAWASAKI HEAVY INDUSTRIES, LTD.

Consumer Products & Machinery Company

TABLE OF CONTENTS

SPECIFICATIONS............................................ 9

GENERAL INFORMATION.............................. 13

Location of Parts ........................................... 13

Side Stand..................................................... 16

Fuel ............................................................... 17

Kick Pedal ..................................................... 19

Starting the Engine........................................ 20

Shifting Gears................................................ 22

Stopping the Motorcycle................................ 23

Stopping the Engine ...................................... 24

Break-In......................................................... 24

Daily Pre-Ride Checks .................................. 26

After-Race Checks ........................................ 28

MAINTENANCE AND ADJUSTMENT............. 29

Periodic Maintenance Chart .......................... 29

Engine Oil...................................................... 34

Cooling System ............................................. 38

Spark Plug..................................................... 41

Air Cleaner .................................................... 43

Throttle Cable................................................ 47

Carburetor ..................................................... 48

Clutch ............................................................ 56

Hot Starter Cable........................................... 61

Valve Clearance ............................................ 62

Exhaust System ............................................ 67

Drive Chain.................................................... 69

Handlebar...................................................... 75

Brakes ........................................................... 77

Steering ......................................................... 81

Front Suspension .......................................... 83

Rear Suspension (UNI-TRAK

®

)..................... 111

Wheels .......................................................... 117

Hoses Inspection........................................... 120

Tightening Torques of Nuts and Bolts............ 121

Cleaning Your Motorcycle.............................. 126

Lubrication..................................................... 128

TROUBLESHOOTING GUIDE......................... 131

ENGINE AND SUSPENSION TUNING............ 139

Carburetor Tuning ......................................... 139

Suspension Tuning........................................ 146

Gearing.......................................................... 152

Special Care According to Track Conditions . 153

OPTIONAL PARTS .......................................... 154

PRE-RACE CHECKS AND AFTER-RACE

MAINTENANCE............................................ 156

STORAGE........................................................ 158

Before Storage .............................................. 158

After Storage ................................................. 159

ENVIRONMENTAL PROTECTION.................. 160

WIRING DIAGRAM .......................................... 161

SPECIFICATIONS 9

SPECIFICATIONS

DIMENSIONS

Overall length 2 170 mm (85 in.)

Overall width 820 mm (32.3 in.)

Overall height 1 270 mm (50 in.)

Wheelbase

1 470 mm (57.9 in.)

Road clearance

340 mm (13.4 in.)

Curb Mass 104.3 kg (230 lb)

Fuel tank capacity

8.0L(2.1USgal)

ENGINE

Type

DOHC, 4-valve, single-cylinder, 4-stroke, liquid-cooled

Bore x stroke

77.0 × 53.6 mm (3.03 × 2.11 in.)

Displacement

249 cm

3

(15.25 cu in.)

Compression ratio

13.2 : 1

Carburetor KEIHIN FCR-MX37

Starting system

Primary kick

Ignition system

AC-CDI

Ignition timing

8° BTDC @2 000 r/min (rpm)

Lubrication system

Forced Lubrication (semi dry sump)

Spark plug NGK CR8E

Spark plug terminal Solid-post

10 SPECIFICATIONS

TRANSMISSION

Transmission type

5-speed, constant-mesh, return shift

Clutch type

Wet, multi disc

Drive system

Chain drive

Gear ratios:

1st gear

2.142 (30/14 )

2nd gear

1.769 (23/13)

3rd gear

1.444 (26/18)

4th gear

1.200 (24/20)

5th gear

1.045 (23/22)

Primary reduction ratio

3.350 (67/20)

Final reduction ratio

3.692 (48/13)

Overall ratio (top gear)

12.931

Engine oil:

Capacity 1.0 L (61.0 cu in.)

Type

API SG, SH, SJ or SL with JASO MA, MA1 or MA2

SAE 10W-40

SPECIFICATIONS 11

FRAME

Type Tubular, semi-double cradle

Steering angle 42° to either side

Castor 27.7°

Trail

122.3 mm (4.8 in.)

Tire size, type: Front

80/100-21 51M, BRIDGESTONE M403

Rear

100/90-19 57M, BRIDGESTONE M404

Rim size: Front 21 × 1.60

Rear 19 × 1.85

Suspension:

Front

Upside-down telescopic fork

Rear New Uni-trak

®

swingarm

Front suspension travel

315 mm (12.4 in.)

Rear wheel travel

310 mm (12.2 in.)

Front fork oil:

Type

SHOWA SS-05 or equivalent

Capacity 361mL(12.2USoz)

Fork cylinder unit

180 mL (6.09 US oz)

12 SPECIFICATIONS

BRAKES

Type (Front & Rear)

Disc

Effective disc diameter:

Front

225mm(8.9in.)

Rear

215mm(8.4in.)

Specifications are subject to change without notice.

GENERAL INFORMATION 13

j

GENERAL INFORMATION

Location of Parts

1. Clutch Lever

2. Engine Stop Button

3. Hot Starter Lever

4. Fuel Tank Cap

5. Front Brake Fluid Reservoir

6. Front Brake Lever

7. Throttle Grip

14 GENERAL INFORMATION

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8. Front Fork

9. Radiator

10. Fuel Tank

11. Fuel Tap

12. Carburetor

13. Seat

14. Air Cleaner Element

15. Brake Disc

16. Brake Caliper

17. Shift Pedal

18. Rear Shock Absorber

19. Swingarm

20. Drive Chain

21. Chain Guide

GENERAL INFORMATION 15

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22. Silencer

23. Rear Brake Fluid Reservoir

24. Rear Shock Absorber Gas Reservoir

25. Uni-Trak

®

Tie Rod and Rocker Arm

26. Kick Pedal

27. Engine Oil Level Inspection Window

28. Rear Brake Pedal

29. Exhaust Pipe

16 GENERAL INFORMATION

j

Side Stand

To install the side stand, insert its flat end into the

rear axle shaft as shown.

A. Side Stand

B. Rear Axle Shaft

WARNING

Do not start the engine or attempt to ride the

motorcycle when the side stand is installed.

NOTE

ż

Support the motorcycle with a suitable stand to

perform maintenance or adjustment procedures.

GENERAL INFORMATION 17

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Fuel

This Kawasaki KX has a 4-stroke engine that re-

quires a gasoline.

The capacity of the fuel tank is 8.0 L (2.1 US gal).

To open the fuel tank cap, pull out the breather hose

from the hole in the steering shaft, and turn the tank

cap counterclockwise.

A. Fuel Tank Cap

B. Breather Hose

WARNING

Gasoline is extremely flammable and can be

explosive 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.

Fuel Requirements:

Fuel Type

Use clean, fresh unleaded gasoline with a mini-

mum Antiknock index of 90. The Antiknock Index is

posted on service station pumps in the U.S.A. The

octane rating of a gasoline is a measure of its re-

sistance to detonation or “knocking”. The Antiknock

Index is an average of the Research Octane Num-

ber (RON) and the Motor Octane Number (MON) as

showninthetablebelow.

Octane Rating Method

Minimum

Rating

(RON + MON)

Antiknock Index

2

90

18 GENERAL INFORMATION

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CAUTION

If engine “knocking” or “pinging” occurs,

use a different brand of gasoline of a higher

octane rating.

If this condition is allowed to continue it can

lead to severe engine damage.

Gasoline quality is important. Fuels of low

quality or not meeting standard industry

specifications may result in unsatisfactory

performance. Operating problems that result

from the use of poor quality or nonrecom-

mended fuel may not be covered under your

warranty.

Fuels Containing Oxygenates

Gasoline frequently contains oxygenates (alco-

hols and ethers) especially in areas of the U.S. and

Canada which are required to sell such reformu-

lated fuels as part of a strategy to reduce exhaust

emissions.

The types and volume of fuel oxygenates ap-

proved for use in unleaded gasoline by the U.S.

Environmental Protection Agency include a broad

range of alcohols and ethers, but only two compo-

nents have seen any significant level of commercial

use.

Gasoline/Alcohol Blends - Gasoline containing up

to 10% ethanol (alcohol produced from agricultural

products such as corn), also known as “gasohol” is

approved for use.

CAUTION

Avoid using blends of unleaded gasoline and

methanol (wood alcohol) whenever possible,

and never use “gasohol” containing more

than 5% methanol. Fuel system damage and

performance problems may result.

Gasoline/Ether Blends - The most common ether

is methyl tertiary butyl ether (MTBE). You may use

gasoline containing up to 15% MTBE.

NOTE

ż

Other oxygenates approved for use in unleaded

gasoline include TAME (up to 16.7%) and ETBE

(up to 17.2%). Fuel containing these oxygenates

canalsobeusedinyourKawasaki.

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Kawasaki KX250F 2009 Owner's manual

Kawasaki KX250F 2009 Owner's manual

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