Kawasaki KLX250 (2009) manual

KLX250 D-TRACKER X Motorcycle Service Manual[...]

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This quick reference guide will assist 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. Quick Reference G[...]

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KLX250 D-TRACKER X 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 Assur ance Division/Motorcycle & Engine Company/Ka[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead cente r m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct [...]

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owne r who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must b[...]

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GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ........................................................................................... .......................... 1-2 Model Identification....................................................................................... .......................... 1-7 Model[...]

1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the preca utions given below . T o facilitate ac tual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever [...]

GENERAL INFORMA TION 1-3 Before Servicing Arrangement and Cleanin g 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 a ssembly . Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the part[...]

1-4 GENERAL INFORMA TION Before Servicing T ightening 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 t[...]

GENERAL INFORMA TION 1-5 Before Servicing 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. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely nec[...]

1-6 GENERAL INFORMA TION Before Servicing 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. Direction of Engin e Rotation When rotating the crankshaft by hand, the fre[...]

GENERAL INFORMA TION 1-7 Model Identification KLX250S9 Left Side View KLX250S9 Right Side View Frame Number Engine Number[...]

1-8 GENERAL INFORMA TION Model Identification KLX250V9 Left Side View KLX250V9 Right Side Vi ew[...]

GENERAL INFORMA TION 1-9 General Specifications Items KLX250S9 SC Dimensions Overall Length 2 200 mm (86.61 in.) Overall Width 820 mm (32.3 in.) Overall Height (IN, EUR, SEA) 1 205 mm (47.44 in.), (TH) 1 190 mm (46.85 in.) Wheelbase 1 430 mm (56.30 in.) Road Clearance 285 mm (1 1.2 in.) Seat Height 890 mm (35.0 in.) Curb Mass: (TH, EUR) 138 kg (304[...]

1-10 GENERAL INFORMA TION General Specifications Items KLX250S9 SC Drive T rain Primary Reduction System: Ty p e Gear drive Reduction Ratio 2.800 (84/30) Clutch T ype Wet multi disc T ransmission: Ty p e 6-speed, constant mesh, return shift Gear Ratios: 1st 3.000 (30/10) 2nd 2.000 (30/15) 3rd 1.500 (27/18) 4th 1.250 (25/20) 5th 1.050 (21/20) 6th 0.[...]

GENERAL INF ORMA TION 1-1 1 General Specifications Items KLX250S9 SC Headlight: Ty p e Semi-sealed beam Bulb (TH) 12 V 30/30 W × 2 (quartz halogen) (IN, EUR, SEA) 12 V 60/55 W (quartz halogen) T ail/Brake Light 12 V 5/21 W Alternator: Ty p e Three-phase AC Rated Output 17.4 A/14 V @5 000 r/min (rpm) Specifications subject to change without notice,[...]

1-12 GENERAL INFORMA TION General Specifications Items KLX250V9 VC Dimensions Overall Length 2 130 mm (83.86 in.) Overall Width 795 mm (31.3 in.) Overall Height (MY , TH) 1 125 mm (44.29 in.) (BR, IN) 1 140 mm (44.88 in.) Wheelbase 1 420 mm (55.91 in.) Road Clearance 225 mm (8.86 in.) Seat Height 860 mm (33.9 in.) Curb Mass: (BR, IN, TH) 139 kg (30[...]

GENERAL INFORMA TION 1-13 General Specifications Items KLX250V9 VC Capacity 1.3 L (1.4 US qt) (when engine is completely dry) Drive T rain Primary Reduction System: Ty p e Gear drive Reduction Ratio 2.800 (84/30) Clutch T ype Wet multi disc T ransmission: Ty p e 6-speed, constant mesh, return shift Gear Ratios: 1st 3.000 (30/10) 2nd 2.000 (30/15) 3[...]

1-14 GENERAL INFORMA TION General Specifications Items KLX250V9 VC Headlight: Ty p e Semi-sealed beam Bulb (MY , TH) 12 V 30/30 W × 2 (quartz halogen) (BR, IN) 12 V 60/55 W (quartz halogen) Ta i l / B r a k e L i g h t 12 V 5/21 W Alternator: Ty p e Three-phase AC Rated Output 17.4 A/14 V @5 000 r/min (rpm)[...]

GENERAL INFORMA TION 1-15 Unit Conversion T able Prefixes for Units Prefix Symbol Power mega M × 1 000 000 kilo k ×1 0 0 0 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume L × 0.2642 = gal (US) L × 0.2200 = gal (IMP) L × 1.057 = qt (US) L × 0.8799 = qt (IMP) L × 2.1[...]

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PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart ................................................................................................... 2-3 T orque and Locking Agent ...................................................................................................... 2-6 Specifications ....[...]

2-2 PERIODIC MAINTENANCE Steering System ................................................................................................................. .2 - 3 6 Steering Play Inspection ................................................................................................... 2-36 Steering Play Adjustment................................[...]

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever comes first * ODOMETER READING × 1 000 km (× 1 000 mile) 1 6 12 1[...]

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first * ODOMETER READING × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 ITEM Every (0.6) (3.75) (7.5) (1 1.25) (15) (18.75) (22.5) See Page Drive chain wear - inspect # • • • 2-29 Drive chain guide wear - inspect • • • 2-30 Brakes Brake fluid leak - inspect ye[...]

PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart *: For higher odome ter readings, repeat at the frequency interval established here. Periodic Replacement Parts FREQUENCY Whichever comes first * ODOMETER READING × 1 000 km (× 1 000 mile) 1 12 24 36 48 ITEM Every (0.6) (7.5) (15) (22.5) (30.0) See Page Air cleaner element # - replace 2 years 2-[...]

2-6 PERIODIC MAINTENANCE T orque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: T ighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L:[...]

PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Camshaft Chain T ensioner Bolts 9.8 1.0 87 in·lb Camshaft Chain Sub-tensioner Bolt 15 1.5 11 Camshaft Chain Guide Bolt 25 2.5 18 Camshaft Chain Guide R etaining Plate Bolt 9.8 1.0 87 in·lb Muffler Body Bolts (Front and Center) 30 3.0 22 Muffler Body Bol[...]

2-8 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Drive Chain Guard Plate Bolts 9.8 1.0 87 in·lb External Shift Mechanism Cover Nut 9.8 1.0 87 in·lb Shift Drum Cam Holder Bolt 12 1.2 106 in·lb L Neutral Switch 14.7 1.5 130 in·lb G Wheels/T ires Spoke Nipples 4.0 0.41 35 in·lb Front Axle Clamp Bolts [...]

PERIODIC MAINTENANCE 2-9 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Steering Steering Stem Nut 4.9 0.50 43 in·lb Handlebar Clamp Bolts 25 2.5 18 S Steering Stem Head Nut 44 4.5 32 Upper Front Fork Clamp Bolts 20 2.0 15 AL Lower Front Fork Clamp Bolts 25 2.5 18 Left Switch Housing Screws 3.5 0.36 31 in·lb Right Switch Ho[...]

2-10 PERIODIC MAINTENANCE T orque and Locking Agent The table below , relating tightening torque to thread diameter , lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic T orque for General Fasten[...]

PERIODIC MAINTENANCE 2-1 1 Specifications Item Standard Service Limit Fuel System (DFI) T h r o t t l eG r i pF r e eP l a y 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 1 300 ±50 r/min (rpm) ––– Air Cleaner Element Polyurethane Foam ––– Air Cleaner Element Oil High quality form air filter oil ––– Cooling System Coolant: T[...]

2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Rear: KLX250S Up to 97.5 kg (215 lb) load: 150 kPa (1.5 kgf/cm², 22 psi) ––– 97.5 ∼ 181 kg (215 ∼ 399 lb) load: 175 kPa (1.75 kgf/cm², 25 psi) ––– KLX250V 225 kPa (2.25 kgf/cm², 33 psi) ––– Rim Runout: Axial: KLX250S TIR 0.7 mm (0.028 in.) or less TIR 2.0 [...]

PERIODIC MAINTENANCE 2-13 Special T ools Inside Circlip Pl iers: 57001-143 Steering Stem Nut W rench: 57001-1 100 Jack: 57001-1238 Spark Plug W rench, Hex 16: 57001-1262 Filler Cap Driver: 57001-1454[...]

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE In dusty areas, the element should be cleaned more frequently than the recommended interval. After riding through rain or on muddily roads, the ele- ment should be cleaned immediately . WA R N I N G Gasoline and low-flash point solvents can[...]

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Throttle Control System Inspection • Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not return properly , check the throt- tle cable routing,[...]

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjus tment • Start the engine and warm it up thoroughly . • T urn the adjusting screw [A] until the idle speed is correct. Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary . Fuel Hose Inspection (fue[...]

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Check the liquid/vapor separator as follows. Disconnect the hoses from the separator , and remove the separator [A] from the motorcycle left side. Visually inspect the separator for cracks and other dam- age. If the separator has any cracks or damage, replace it with a new one. T o preve[...]

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose Inspection (coolant l eak, damage, installation condition) The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. • Visua lly inspect the hoses for signs of deterioration. Squeeze the hoses. A hose[...]

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures V alve Clearance Ad justment • Remove the camshaft [A] (see Camshaft Removal in the Engine T op End chapter). • Remove the valve lifter [B] of a valve that requires an adjustment. • Remove the shim [C] on the spring reta iner . NOTE Mark the shim and valve lifter so that they can be in[...]

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures V alve Clearance Adjustment Charts Inlet 1. Measure the valve clearance (when cold). 2. Check the present shim size. 3. Select an optimum shim based on a measured cl earance value (row headings) and the thickness of the shim currently in use (column headings). 4. The cell where the row and l[...]

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures V alve Clearance Adjustment Charts Exhaust 1. Measure the valve clearance (when cold). 2. Check the present shim size. 3. Select an optimum shim based on a measured cl earance value (row headings) and the thickness of the shim currently in use (column headings). 4. The cell where the row and[...]

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Suction System Damage Inspection • Remove the fuel tank (see Fuel T ank Removal in the Fuel System (DFI) chapter). • Separate the air switching valve hose [A] from the air cleaner housing. • Install the fuel tank temporary (see Fuel T ank Installation in the Fuel System (DFI) chapt[...]

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures WA R N I N G The engine and exhaust system get extremely hot during normal operation and can caus e serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • Slide the dust cover [A] at the clutch cable. • Loosen the locknut [B] at the middle of the clutch cable. [...]

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tire T read Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are b[...]

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Raise the rear wheel of f the ground with jack. Special T ool - Jack: 57001-1238 • Inspect the roughness of the rear wheel bearing by mov- ing the wheel with both hands to both s ides. • Spin [A] the rear wheel lightly , and check for smoothly turn, roughness, binding or noise. If ro[...]

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the front/rear wheel off the ground with jack. Special T ool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warp- ing. 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 measur[...]

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. • Wipe off any excess oil. Oil Applied Areas [A] O-rings [B] Drive Chain Slack Inspection NOTE Check the slack with th[...]

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment. It should be within 30 degrees. Loosen one and tighten again when the slot goes past the nearest hole. WA R N I N G A loose[...]

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). • 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 c hain. Lubricate the drive chai[...]

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Chain Guide Wear Inspection • Visua lly inspect the following parts. Front Chain Guide [A] Rear Chain Guide [B] Chain Slipper [C] Chain Guide Roller [D] If the chain guides, chain slipper and chain guide roller show any signs of abnormal wear or damage, replace them.[...]

PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake System Brake Fluid Leak Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. If the brake fluid leaked from any position, inspect or re- place the problem part.[...]

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Damage and Installation Condition Inspection • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. 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 t[...]

PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WA R N I N G Mixing brands and types of brake fluid can reduce the brake system’ s [...]

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust the brake light switch. • While holding the switch body , turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] NOTICE T o avoid damaging the electrical connections in- sid[...]

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Visually inspe ct the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary . Rear Shock Absorber Oil Leak Insp ection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the[...]

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tie-Rod Operation Inspection • Pump the tail grip down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rods [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/T ie-Rod Bearing, Sleeve Inspection in the Suspen- sion chapte[...]

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Steering Pla y Adjustment • Remove: Handlebar (see Handlebar Removal in the Steering chapter) • Loosen: Lower Fork Clamp Bolts (see Front Fork Removal in the Suspension chapter) Steering Stem Head Nut [A] • Adjust the steering stem nut [C], using the steering stem nut wrench [B]. Speci[...]

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Set the lighting switch to ON position (IN model). • T urn the i gnition switch ON. • The following lights should go on according to below table. T ailligh t [A] g[...]

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Second Step • T urn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. • The turn signal indicator light (LED) [C] in the meter unit should flash. If the each light does no[...]

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Forth Step • Set the lighting switch to ON position. • Set the dimmer switch [A] to low beam position. • T urn the i gnition switch ON. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following item. Headlight Bulb (see Headli[...]

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Headlight Beam V ertical Adjustment • T urn the vertical adjuster [A] on the headlight with the screwdriver in or out to adjust the head light vertically . IN and Europe Models [B] MY and TH Models [C] NOTE ON high beam, the brightest points should be slightly below horizontal with the mot[...]

2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Battery Condition in the Electrical System chapter) Main Fuse 20 A (see Fuse Inspection in the Electrical System chapter) ECU Fuse 15 A (see Fuse Inspection in the Electrical System chapter) [...]

PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe of f 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 conditi[...]

2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the cable disconnected at 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.[...]

PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. 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 th[...]

2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE In dusty areas, the element should be replaced more frequently than the recommended interval. After riding through rain or on muddily roads, the ele- ment should be replaced immediately . WA R N I N G If dirt or dust is allowed to pass t[...]

PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Install the frame into the new element. • Coat the lip of the element wit h a thick layer of all pur- pose grease [A] to assure a complete seal against the air cleaner element base. Also, c oat the base where the lip of the element fits. • Install the element, and tighten the wring b[...]

2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Be sure to place a piece of cloth [A] around the fuel outlet hose joint. • Insert a minus screw driver [B] into the slit [C] on the joint lock. • T urn the driver to disconnect the joint lock [D]. • Pull the fuel hose joint [A] out of the delivery pipe [B]. • Replace the fuel hos[...]

PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Coolant Change WA R N I N G 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 o[...]

2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer ’s directions. NOTICE Soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the syste m, it causes scales accumulation in the water pa[...]

PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Radiator Hose and O-ring Replacemen t • Drain the coolant (see Coolant Change). • Remove: W ater Hose Fitting [A] W ater Pump Impeller [B] (see W ater Pump Removal in the Cooling System chapter) O-rings [C] Hoses [D] • Apply grease to the new O-rings and install them. • T ighten: T o[...]

2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Recommended Engine Oil Ty p e : API SG, SH , SJ, SL or SM with JA SO MA, MA1 or MA2 Vis c os i ty : SAE 10W-4 0 Capacity: 1.0 L (1.1 US qt) (when filte r is not remove d) 1.1 L (1.2 US qt) (whe n filter is removed ) 1.3 L (1.4 US qt) (when engine i s completely dry) NOTE Do not add any chemi[...]

PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Replace the O-ring [A] of the filter cap with a new one. • Apply engine oil to the O-ring. • Install the oil filter cap so that the align the oil passage holes [B] of the oil filter cap and right engine cover . • Pour in the specified type and amount of oil (see Engine Oil Change).[...]

2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change 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 . • Remove the reservoir ca p and diaphragm. • Remove the rubber cap from the bleed valve [A] on th[...]

PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replaceme nt Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap [A] and diaphragm [B], and pour the brake fluid into a container . • Unscrew the locknu[...]

2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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 brake parts. Do not use any other fluid for cleaning[...]

PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly • Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) • Using compressed air , remove the pistons. Cover the piston area with a clean, thick cloth[...]

2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the anti-rattle spring [A] as shown. • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • Check the shaft rubber friction boot [A] and the dust boot [B] replace them with new ones if they are damaged. • Apply a thin coat of PBC (Pol[...]

PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Rear 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. • Install the bleed valve and rubber cap. T o rque - Blee d V alv e: 7. 8 N·m (0.8 0 kgf·m, 6 9 in·lb) • Replace the[...]

2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spark Plug Replacement • Remove the left radiator shroud (see Radiator Shroud Re- moval in the Frame System chapter). • Remove the spark plug cap [A] from the spark plug. • R e m o v et h es p a r kp l u gu s i n gt h ep l u gw r e n c hv e r t i c a l l y . Special T ool - Spark Plug [...]

FUEL SYSTEM (DFI) 3-1 3 Fuel System (DFI) T able of Contents Exploded View ................................................................................................................... ..... 3-4 DFI System ...................................................................................................................... ....... 3-10 DFI Pa[...]

3-2 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32: TH and EUR Models/Service Code 62: IN and MY Models) ........................................................................................................... ..................... 3-66 Subthrottle Sensor Removal/Adjustment .................................................................[...]

FUEL SYSTEM (DFI) 3-3 Fuel Pump Operating V oltage Inspection ......................................................................... 3-102 Pressure Regulator Removal ............................................................................................ 3-103 Fuel Filter Cleaning .............................................................[...]

3-4 FUEL SYSTEM (DFI) Exploded View[...]

FUEL SYSTEM (DFI) 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Air Cleaner Duct Clamp Screw 2.0 0.20 18 in·lb 2 ECU Bracket Screws 5.0 0.51 44 in·lb 3 Inlet Air T emperature Sensor Mounting Screw 1.2 0.12 11 i n · l b 4 Throttle Pulley Cover Screws 5.0 0.51 44 in·lb 5. Air Switching V alve 6. Fuel Injector 7. Thrott[...]

3-6 FUEL SYSTEM (DFI) Exploded View[...]

FUEL SYSTEM (DFI) 3-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel Pump Bolts 9.8 1.0 87 in·lb L 2 V ehicle-down Sensor Mounting Bolts 6.9 0.70 61 in·lb 3 W ater T emperature Sensor 12 1.2 106 in·lb 4 Oxygen Sensor 25 2.5 18 5. Fuel Pump Relay 6. Speed Sensor 7. Fuel Pump 8. V ehicle-down Sensor 9. IN and EUR Models 10. T[...]

3-8 FUEL SYSTEM (DFI) Exploded View SEA and TH Models[...]

FUEL SYSTEM (DFI) 3-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Separator Bracket Bolts 9.8 1.0 87 in·lb 2. Canister 3. Separator 4. Green/White Hose 5. Blue Hose 6. Red H ose 7. White Hose[...]

3-10 FUEL SYSTEM (DFI) DFI System DFI System[...]

FUEL SYSTEM (DFI) 3-1 1 DFI System 1. Battery 12 V 6 Ah 2. ECU 3. Fuel T ank 4. Pressure Regulator 5. Fuel Pump 6. Air Switching V alve 7. Inlet Air Pressure Sensor 8. Fuel Injectors 9. Crankshaft Sensor 10. W ater T emperature Sensor 1 1. Main Throttle Sensor 12. Subthrottle Sensor 13. Subthrottle V alve Actuator 14. Air Cleaner Housing 15. Oxygen[...]

3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram[...]

FUEL SYSTEM (DFI) 3-13 DFI System Part Names 1. Ignition Switch 2. Fan Motor 3. Radiator Fan Relay 4. Meter Unit 5. W ater T emperature W arning Indicator Light (LED) 6. FI Indicator Light (LED) 7. T achometer 8. Fuel Pump 9. Fuel Pump Relay 10. Ignition Coil 1 1. Spark Plug 12. Crankshaft Sensor 13. ECU 14. Starter Relay 15. Main Fuse 20 A 16. Bat[...]

3-14 FUEL SYSTEM (DFI) DFI System T erminal Numbers of ECU Con nectors T erminal Names 1. Power Supply to ECU (from Ignition Switch) 2. V ehicle-down Sensor 3. Crankshaft Sensor (+) 4. Unused 5. Main Throttle Sensor 6. Inlet Air Pressure Sensor 7. Oxygen Sensor 8. Ground for Control System 9. Crankshaft Sensor 10. External Communication Line (*KDS)[...]

FUEL SYSTEM (DFI) 3-15 DFI System 35. Ground for ECU 36. Ground for ECU *: KDS (Kawasaki Diagnostic System)[...]

3-16 FUEL SYSTEM (DFI) DFI Parts Location ECU [A] Self-diagnosis T erminal [A] Kawasaki Diagnostic System Connector [B] Oxygen Sensor [C] Fuel Pump [A] Fuel Pump Relay [B] Throttle Body Assy [C] Inlet Air T emperature Sensor [A] Main Throttle Sensor [A][...]

FUEL SYSTEM (DFI) 3-17 DFI Parts Location V ehicle-down Sensor [A] Subthrottle Sensor [B] W ater T emperature Sensor [C] Subthrottle V alve Actuator [D] Fuel Injector [A] Inlet Air Pressure Sensor [B] Ignition Coil [A] Air Switching V alve [B] Speed Sensor [A] E C UF u s e1 5A[ A ][...]

3-18 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ± 50 r/min (rpm) Throttle Body Assy: Ty p e Single barrel Bore 34 mm (1.34 in.) ECU: Make KEIHIN Ty p e Digital memory type, with built in IC igniter , sealed with resin Fuel Pressure (High Pressure Line) 294 kPa (3.0 k gf/cm², 43 psi) with engine i[...]

FUEL SYSTEM (DFI) 3-19 Specifications Item Standard Output V oltage DC 0.48 ∼ 0.52 V at subthrottle valve full close position DC 3.8 ∼ 4.0 V at subthrottle v alve full open position (for reference) Resistance 4 ∼ 6k Subthrottle V alve Actuator: Resistance About 5.2 ∼ 7.8 Input V oltage About DC 10.5 ∼ 12.5 V , and then 0 V Oxygen Sensor: [...]

3-20 FUEL SYSTEM (DFI) Special T ools and Sealant Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Jack: 57001-1238 Hand T ester: 57001-1394 Throttle Sensor Se tting Adapter #1: 57001-1400 Peak V oltage Adapter: 57001-1415 Needle Adapter Set: 57001-1457 Throttle Sensor Sett ing Adapter: 57001-1538 Fuel Pressure Gauge Adapt er: 57001-1593 Fuel Hose: 57001-[...]

FUEL SYSTEM (DFI) 3-21 Special T ools and Sealant Liquid Gasket, TB121 1: 56019-120[...]

3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. Do not revers[...]

FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions 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 T ank Removal) and check the fuel hose. Fuel Inlet Hose [A] Fuel Outlet Hose [B] Replace the fuel hose if any fraying, cracks or bulges are n[...]

3-24 FUEL SYSTEM (DFI) T roubleshooting the D FI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the c ondition of the problem is stored in the memory of the ECU (Electronic Control Unit). With the engine stopped and turned in th[...]

FUEL SYSTEM (DFI) 3-25 T roubleshooting the DFI System • 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 [...]

3-26 FUEL SYSTEM (DFI) T roubleshooting the D FI System • 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. Connect the connectors securely . • Check the wiring for continuity . Use the wiring diagram to find the ends of the le[...]

FUEL SYSTEM (DFI) 3-27 T roubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Each rider reacts to problems in dif ferent ways, so it is important to confirm what kind of symptoms the rider has encountered. T ry to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information[...]

3-28 FUEL SYSTEM (DFI) T roubleshooting the D FI System Sample Diagnosis Sheet Rider name Registration No. (license plate No.) Y ear of initial registration Model Engine No. Frame No. Date problem occurred Mileage Environment when problem occurred. Weather fine, cloudy , rain, snow , always, other: T emperature hot, warm, cold, very cold, always ch[...]

FUEL SYSTEM (DFI) 3-29 T roubleshooting the DFI System engine overheating. clutch slipping. other: spark plug loose (tighten it). spark plug dirty , broken, or gap maladjusted (remedy it). spark plug incorrect (replace it). knocking (fuel poor quality or incorrect). brake dragging. clutch slipping. engine overheating. engine oil level too high. eng[...]

3-30 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide NOTE This is not an exhaustive list, giving every pos sible 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 t[...]

FUEL SYSTEM (DFI) 3-31 DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). W ater temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Main throttle[...]

3-32 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Spark plug dirty , broken or gap maladjusted Inspect and replace (see chapter 16). Ignition coil trouble Inspect (see chapter 16). Stumble: Fuel pressure too low Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle[...]

FUEL SYSTEM (DFI) 3-33 DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Spark plug dirty , broken or gap maladjusted Inspect and replace (see chapter 16). Spark plug incorrect Replace it with the correct plug (see chapte r 2). ECU trouble Inspect (see chapter 3). Fuel/air mixture incorrect: Air cleaner clogged, poorly[...]

3-34 FUEL SYSTEM (DFI) DFI System T roubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel injector trouble Inspect (see chapter 3). W ater temperature sens or trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). (Brown smoke) Air cleaner housing loose Reinstall (see chapter 3). Fuel pressu[...]

FUEL SYSTEM (DFI) 3-35 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by grounding the s elf-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty , and[...]

3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Flow Chart[...]

FUEL SYSTEM (DFI) 3-37 Self-Diagnosis How to Read Service Codes Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below . Read 10th digit and unit digit as the FI indicator light (LED) blinks. When there are a number of problems, all the service codes can be stored and the display will begin start[...]

3-38 FUEL SYSTEM (DFI) Self-Diagnosis Service Code T a ble Ser- vice Code FI Indicator Light (LED) Problems 11 Main throttle sensor malfunction, wiring open or short 12 Inlet air pressure sensor malfunction, wiring open or short 13 Inlet air temperature sensor malfunction, wiring open or short 14 W ater temperature sensor malfunction, wiring open o[...]

FUEL SYSTEM (DFI) 3-39 Self-Diagnosis 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 t[...]

3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 11 Main Throttle Sensor Main Throttle Sensor Output V oltage 0.410 ∼ 4.375 V If the main throttle sensor syst[...]

FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU Subthrottle Sensor Subthrottle Sensor Output V oltage 0.35 V ∼ 4.90 V TH and EUR Models If the subthrottle sensor system fails (the signal is out of the usable range, wiring short or open), the actuator locks subthrottle valve at full o[...]

3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Codes Parts Output Signal Usable Range or Criteria Backups by ECU 64 Air Switching Va l v e The air switching valve solenoid opens and shuts the air switching valve according to the signal from the ECU. ECU does not backup. 67 Oxygen Sensor Heater The oxygen sensor heater raise temperature of the sensor[...]

FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 1 1 ) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity , and ignition timing according to engine rpm, and throttle opening. Input T erminal [A] Outp[...]

3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 1 1) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Disconnect the ECU and sensor connectors. Wiring Insp ection ECU Connector [A] Main Throttle Sens or Connector [B] BL lead (ECU terminal 13) [C] BR/BK lead (ECU ter[...]

FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 1 1 ) • T urn the ignition switch OFF . • Measure the output voltage with the engine stopped and with the connector joined. • T urn the i gnition switch ON. Output V oltage Standard: DC 0.585 0.615 V at idle th rottle opening DC 3.7 3.9 V at f ull throttle openi ng (for reference) NOTE[...]

3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 1 1) Main Throttle Sen sor Resistance Inspection • Disconnect the main throttle sensor connector . • Connect a harness adapter [A] to the main throttle sensor . Special T ool - Throttle Sensor Setting Adapter: 57001 -1538 Main Throttle Sensor Resi stance Connections to Adapter: Digital M[...]

FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Servi ce Code 12) Inlet Air Pressure Sensor Removal NOTICE Never drop the inlet air pressure sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel T ank (see Fuel T ank Removal) Inlet Air Pressure Sensor Connector [A] Screw [B] Plate [C] • Remove the inlet[...]

3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) • T ighten the screw [A] securely . • Connect the inlet air pressure sensor connector [B]. Inlet Air Pressure Se nsor Input Voltage Inspection NOTE Be sure the battery is fully charged. • T urn the ignition switch OFF . • Disconnect the inlet air pressure sensor connector an[...]

FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Servi ce Code 12) Inlet Air Pressure Sensor Output Voltage Inspection • Measure the output voltage at the inlet air pressure sen- sor in the same way as input voltage inspection, note the following. Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between thes[...]

3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle V acuum Pressure (Absolute) ST : Standard of Sensor Output V oltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output V oltage (V) Vv: Inlet Air Pressure Sensor Output V oltage (V) (Digital Meter Reading[...]

FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Servi ce Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. W ater-proof Joint 3. Inlet Air Pressure Sensor[...]

3-52 FUEL SYSTEM (DFI) Inlet Air T emperature S ensor (Service Code 13) Inlet Air T emperature Sensor Removal/Installation NOTICE Never drop the inlet air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the seat (see Seat Removal in the Frame chap- ter). • Disconnect the connector [A] from t[...]

FUEL SYSTEM (DFI) 3-53 Inlet Air T emperature S ensor (Service Code 1 3) • T urn the ignition switch OFF . If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is out of the s[...]

3-54 FUEL SYSTEM (DFI) Inlet Air T emperature S ensor (Service Code 13) Inlet Air T emperature S ensor Circuit 1. ECU 2. W ater-proof Joint 3. Inlet Air T emperature Sensor[...]

FUEL SYSTEM (DFI) 3-55 W ater T emperature Sensor (Service Code 14) Water T emperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Connector [A] W ater T e[...]

3-56 FUEL SYSTEM (DFI) W ater T emperature Sen sor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Disconnect the ECU and sensor connectors. Wiring Insp ection ECU Connector [A] W a ter T emperature Sensor Connector [ B] GY lead (ECU termin al 22) [C ] BR/B[...]

FUEL SYSTEM (DFI) 3-57 Crankshaft Sensor (Se rvice 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 Starter Coil Removal/Installation in th e Elec- trical Sy stem ch apter . Crankshaft Sensor Resistance Inspe ction •[...]

3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter . Speed Sensor I nput V oltage Inspection NOTE Be sure the battery is fully charged. • T urn the ignition switch OFF . • Remove the head light body (see Head Light Body Re- m[...]

FUEL SYSTEM (DFI) 3-59 Speed Sensor (Service Code 24) If the speed sensor power supply v oltage is within the standard, check the wiring for continuity between main harness connectors. Wiring Insp ection Speed Meter Connector [A] Speed Sensor Connector [B] R lead [C] Battery Negative (–) T erminal [D] Speed Sensor Connector [E] BK/Y lead [F] If t[...]

3-60 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) If the reading is within the standard, remove the E CU and check the wiring for continuity between main harness con- nectors. Disconnect the ECU and sensor connectors. Wiring Insp ection ECU Connector [A] Speed Sensor Connect or [B] G/R lead (ECU terminal 26) [C] If the wiring is good, check the[...]

FUEL SYSTEM (DFI) 3-61 V ehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes. The ECU senses this change, and stops the fuel pump relay , the fuel inject[...]

3-62 FUEL SYSTEM (DFI) V ehicle-down Sensor (Service Code 31) V ehicle-down Sensor Installation • The UP mark [A] of the sensor should face upward. • T ighten: T orque - V ehicle-down Sensor Mounting Bolts: 6.9 N·m (0.70 kgf ·m, 6 1 in·lb) • Apply dielectric grease (approximate 1 g) betwee n the ter- minals of vehicle-down sensor . WA R N [...]

FUEL SYSTEM (DFI) 3-63 V ehicle-down Sensor (Service Code 31) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Disconnect the ECU and sensor connectors. Wiring Insp ection ECU Connector [A] V ehicle-down Sensor Connector [B] BL lead (ECU terminal 13) [C] BR/BK lead (ECU ter m[...]

3-64 FUEL SYSTEM (DFI) V ehicle-down Sensor (Service Code 31) • Hold the sensor vertically . • Measure the output voltage with the engine stopped and with the connector joined. • T urn the i gnition switch ON. • T ilt the sensor 60 ∼ 70° or more [A] right or left, then hold the sensor almost vertical with the arrow mark pointed up [B], a[...]

FUEL SYSTEM (DFI) 3-65 V ehicle-down Sensor (Service Code 31) V eh icle-down Sensor Circuit 1. ECU 2. W ater-proof Joint 3. V ehicle-down Sensor[...]

3-66 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32: T H and EUR Models/Service Code 62: IN and MY Models) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity , and ignition timing according to engine rpm[...]

FUEL SYSTEM (DFI) 3-67 Subthrottle Sensor (Service Code 32: TH and EUR Models/Service Code 62: IN and MY Models) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Disconnect the ECU and sensor connectors. Wiring Insp ection ECU Connector [A] Subthrottle Sensor C onnector [B] B[...]

3-68 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32: T H and EUR Models/Service Code 62: IN and MY Models) • Measure the output voltage with the engine stopped with the connector joined. • T urn the i gnition switch ON. • Measure the output voltage when the subthrottle valve is completely closed by turning the lever [A] fully clockwise[...]

FUEL SYSTEM (DFI) 3-69 Subthrottle Sensor (Service Code 32: TH and EUR Models/Service Code 62: IN and MY Models) Subthrottle Sensor Resistance Inspec tion • Disconnect the subthrottle sensor connector . • Connect a harness adapter [A] to the subthrottle sensor . • Measure the subthrottle sensor resistance. Special T ool - Throttle Sensor Sett[...]

3-70 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter . Oxygen Sensor In spection • W arm up the engine thoroughly until the radiator fan starts. • T urn the ignition switch OFF . • Remove: Seat (see Seat Re[...]

FUEL SYSTEM (DFI) 3-71 Oxygen Sensor - not activated (Service Code 33) • Pull the air switching valve [A] from frame bracket. Do not disconnect the air switching valve connector [B]. • Install the suitable plug [C] on the fitting of the air suction valve cover , and shut off the secondary air . • Start the engine, and let it idle. • Measure[...]

3-72 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Ci rcuit 1. Ignition Switch 2. ECU 3. Starter Relay 4. Main Fuse 20 A 5. Battery 12 V 6 Ah 6. Fuse Box 7. Ignition Fuse 10 A 8. Oxygen Sensor 9. W ater-proof Joint[...]

FUEL SYSTEM (DFI) 3-73 Fuel Injector (Service Code 41) Fuel Injector Removal • Remove the fuel tank (see Fuel T ank Removal). • Be sure to place a piece of cloth [A] around the fuel hose joint. • Insert the screw driver [B] to the joint lock slit [C]. • T urn the driver to disconnect the joint lock [D]. • Pull the fuel hose joint [A] out [...]

3-74 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) • Fit the fuel injector [B] between the projections [A] on the delivery pipe. • Fit the projection [A] on the delivery pipe to the hollow [B] of the throttle body assy . • T ighten the delivery pipe mounting screws [A] • Connect the fuel injector connector [B]. • Insert the fuel hose [...]

FUEL SYSTEM (DFI) 3-75 Fuel Injector (Service Code 41) Fuel Injector Audible Inspection NOTE Be sure the battery is fully charged. • Remove: Fuel T ank (see Fuel T ank Removal) Fuel Outlet Hose (see Fuel Injector Removal) • Connect the following parts. Fuel Pump Lead Connector Fuel Hose [A] Special T ool - Fuel Hose: 57001-1607 • Start the en[...]

3-76 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) Fuel Injector Power Supply V oltage Inspection NOTE Be sure the battery is fully charged. • T urn the ignition switch OFF . • Disconnect the injector connector and connect the mea- suring adapter [A] between these connector . Main Harness [B] Fuel Injector [C] Special T ool - Measuring Adap[...]

FUEL SYSTEM (DFI) 3-77 Fuel Injector (Service Code 41) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Disconnect the ECU and injector connectors. Wiring Insp ection ECU Connector [A] Fuel Injector connector [B] O/W lead (ECU terminal 16) [C] If the wiring good, check the EC[...]

3-78 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) Fuel Injector Circu it 1. Ignition Switch 2. ECU 3. Starter Relay 4. Main Fuse 20 A 5. Battery 12 V 6 Ah 6. Fuse Box 7. Ignition Fuse 10 A 8. Fuel Injector 9. Starter Button 10. Engine Stop Switch[...]

FUEL SYSTEM (DFI) 3-79 Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal NOTICE Never drop the fuel pump relay especially on a hard surface. Such a shock to the relay can damage it. • Remove the right radiator shroud (see Radiator Shroud Removal in the Frame chapter). • Remove the fuel pump relay [A] and disconnect the con- nector . Fue[...]

3-80 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 46) Fuel Pump Relay Circuit 1. Ignition Switch 2. Fuel Pump 3. Fuel Pump Relay 4. ECU 5. Starter Relay 6. Main Fuse 20 A 7. Battery 12 V 6 Ah 8. Frame Ground 9. Fuse Box 10. Ignition Fuse 10 A 1 1 . E C UF u s e1 5A 12. Starter Button 13. Engine Stop Switch[...]

FUEL SYSTEM (DFI) 3-81 Ignition Coil (Service Code 51) Ignition Coil Removal/Installation • Refer to the Ignition Coil Removal/Installation in the Elec- trical Sy stem ch apter . Ignition Coil Input V oltage Inspection NOTE Be sure the battery is fully charged. • T urn the ignition switch OFF . • Remove the ECU (see ECU Removal). Do not disco[...]

3-82 FUEL SYSTEM (DFI) Ignition Coil (Service Code 51) Ignition Coil Circuit 1. Ignition Switch 2. Ignition Coil 3. Spark Plug 4. ECU 5. Starter Relay 6. Main Fuse 20 A 7. Battery 12 V 6 Ah 8. Frame Ground 9. Fuse Box 10. Ignition Fuse 10 A 1 1. ECU Fuse 15 A[...]

FUEL SYSTEM (DFI) 3-83 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Refer to the Radiator Fan Relay Inspection in the Electri- cal System chapter . Radiator Fan Relay Inspection • Refer to the Radiator Fan Relay Inspection in the Electri- cal System chapter . If the radiator fan relay is normal, check the wirin[...]

3-84 FUEL SYSTEM (DFI) Subthrottle V alve Actuator (S ervice Code 62: TH and EUR Models/Service Code 32: IN and MY Models) Subthrottle V alve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory . Never drop the throttle body assy especially on a hard surface. Such[...]

FUEL SYSTEM (DFI) 3-85 Subthrottle V alve Actuator (Service Code 62: TH and EUR Models/Service Code 32: I N and MY Models) • Connect a digital meter to the subthrottle valve actuator connector . • Measure the subthrottle valve actuator resistance. Subthrottle V alve Actuator Resistance Connections: G lead [1] W/BL lead [ 2] BK lead [3] P lead [[...]

3-86 FUEL SYSTEM (DFI) Subthrottle V alve Actuator (S ervice Code 62: TH and EUR Models/Service Code 32: IN and MY Models) If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. Disconnect the ECU and actuator connectors. Wiring Insp ection ECU Connector [A] Subthrottle V alve[...]

FUEL SYSTEM (DFI) 3-87 Air Switching V alve (Service Code 64) Air Switching V alve Removal/Installation • Refer to the Air Switching V alve Removal/Installation in the Engine T op End chapter . Air Switching V alve Inspection • Refer to the Air Switching V alve Unit T est in the Electrical System chapter . If the air switching valve is normal, [...]

3-88 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) Oxygen Sensor Heater Re moval/Installation The oxygen sensor heater is built in the oxygen sensor . So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter). Oxygen Sensor Heater Resistance Inspection • T urn the [...]

FUEL SYSTEM (DFI) 3-89 Oxygen Sensor Heater (Servi ce Code 67) If the wiring is good, remove the ECU and check the wiring for continuity between main harness connectors. Disconnect the ECU and sensor connectors. Wiring Insp ection ECU Connector [A] Oxygen Sensor Connector [B] Y lead (ECU terminal 17) [C] If the wiring is good, check the ECU for its[...]

3-90 FUEL SYSTEM (DFI) FI Indicator Light (LED) FI Indicator Light (LED) Inspection In this model, the FI indicator light (LED) [A] blink by the data sent from the ECU. • Refer to the Meter Unit Inspection in the E lectrical System chapter for the FI indicator lig ht (LED) inspection. FI Indicator Light (LED) Circuit 1. ECU 2. Meter Uni t 3. Igni[...]

FUEL SYSTEM (DFI) 3-91 FI Indicator Light (LED) Inspection F low Chart[...]

3-92 FUEL SYSTEM (DFI) 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 can not clear the regulation. ECU Identifica tion Part Number [A] Specificat ion EUR (KLX250S9) 21 175-0167 TH (KLX[...]

FUEL SYSTEM (DFI) 3-93 ECU • Remove: ECU Connector [A] ECU [B] ECU Installation • Install the ECU [B] to the rubber protector [A]. • Connect the ECU connector . • Apply dielectric grease (approxima te 1 g) between the ter- minals of ECU. • Insert the slits [A] of the rubber protector to the air cleaner housing bracket. ECU Power Supply In[...]

3-94 FUEL SYSTEM (DFI) ECU • T urn the ignition switch OFF . • Disconnect the ECU connectors [A]. • Set the hand tester [B] to the × 1 range and check the following wiring for continuity . Special T ool - Hand T ester: 57001-1394 ECU Grounding Inspection Connections: (I) BK/Y leads (ECU terminal 8, 35 or 36) Battery (–) T erminal (II) Engi[...]

FUEL SYSTEM (DFI) 3-95 ECU ECU Power Supply Circuit 1. Ignition Switch 2. ECU 3. Starter Relay 4. Main Fuse 20 A 5. Battery 12 V 6 Ah 6. Frame Ground 7. Fuse Box 8. Ignition Fuse 10 A 9. ECU Fuse 15 A[...]

3-96 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Fuse Box Fuse Removal in the Electrical Sys- tem chapter . ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. • Refer to the Fuse Installation in the Electrical Syste[...]

FUEL SYSTEM (DFI) 3-97 Fuel Line Fuel Pressure Inspection NOTE Be sure the battery is fully charged. • Remove: Fuel T ank (see Fuel T ank Removal) Fuel Outlet Hose (see Fuel Injector Removal) 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 . WA R N I N G Fuel is flamma[...]

3-98 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idlin g) S t a n d a r d : 2 9 4k P a( 3 . 0k g f / c m ² ,4 3p s i ) NOTE The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • T urn the i[...]

FUEL SYSTEM (DFI) 3-99 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the fuel outlet hose from t he fuel pump (see Fuel T ank Removal). Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. WA R N I N G Fuel is flammable and explosive under certain con- ditions and can cause severe [...]

3-100 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T urn the ignitio[...]

FUEL SYSTEM (DFI) 3-101 Fuel Pump 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. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • T ighten: T orque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf· m, 87 in·lb) ?[...]

3-102 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating V oltage Inspection NOTE Be sure the battery is fully charged. • T urn the ignition switch OFF . • Remove the right side cov er (see Side Cover Removal in the Frame chapter). • Disconnect the fuel pump lead connector [A] and con- nect the harness adapter [A] between these conne ctors as sh[...]

FUEL SYSTEM (DFI) 3-103 Fuel Pump Pressure Regulator Removal The pressure regulator [A] is built into the fuel pump [B] 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.[...]

3-104 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. Ignition Switch 2. Fuel Pump 3. Fuel Pump Relay 4. ECU 5. Starter Relay 6. Main Fuse 20 A 7. Battery 12 V 6 Ah 8. Frame Ground 9. Fuse Box 10. Ignition Fuse 10 A 1 1. ECU Fuse 15 A 12. Starter Button 13. Engine Stop Switch[...]

FUEL SYSTEM (DFI) 3-105 Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter . Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter . Throttle Cable Remove • Remove the screws [A][...]

3-106 FUEL SYSTEM (DFI) Throttle Grip and Cables KLX250V Model • Remove the clip [A]. • Remove the throttle cable from holder [B] and remove the cable lower ends [C] from the throttle pulley . • Pull out the throttle cable from the frame. Throttle Cable Installation • Lubricate the cable. • Apply grease to the upper and lower ends of the [...]

FUEL SYSTEM (DFI) 3-107 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows. Remove the throttle body assy (see Throttle Body Assy Removal). Check the throttle bore [A] at the main throttle valve for carb[...]

3-108 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Bolts [A] V ehicle-down Sensor (with Bracket) [B] Subthrottle Sensor Connector [C] • Remove the throttle body assy from air cleaner duct and remove from the throttle body holder . • Remove the throttle body assy upward. Throttle Body Assy Installation • Install the throttle body assy so t[...]

FUEL SYSTEM (DFI) 3-109 Throttle Body Assy • Pull out the injector [A] from the delive ry pipe [B]. NOTE Do not damage the insertion portions of the injector when they are pulled out from the delivery pipe. NOTICE Never drop the fuel injector especially on a hard surface. Such a shock to the injector can d amage it. Throttle Body Assy Assembly ?[...]

3-1 10 FUEL SYSTEM ( DFI) Throttle Body Assy • Install the plate so that fit the projection [A] on the plate and hollow [B] on the throttle bod y assy . • T ighten the plate mounting screw securely .[...]

FUEL SYSTEM (DFI) 3-1 1 1 Air Cleaner Air Cleaner Element Removal/Ins tallation • Refer to the Air Cleaner E lement Replacement in the Pe- riodic Maintenance chapter . Air Cleaner Element Inspection • Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter . Air Cleaner Housing Removal • Remove: Right and Left Side Cover[...]

3-1 12 FUEL SYSTEM ( DFI) Air Cleaner Air Cleaner Ho using Installation • Fit the projection [A] of the air cleaner housing into the groove [B] of the air cleaner duct. • T ighten the clamp screw securely . • Run the removed hoses properly (see Cable, Wire and Hose Routing in the Appendix chapter).[...]

FUEL SYSTEM (DFI) 3-1 13 Fuel T ank Fuel T ank Remov al WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T urn the ign[...]

3-1 14 FUEL SYSTEM ( DFI) Fuel T ank • Be sure to place a piece of cloth [B] around the fuel outlet hose joint [A]. • Remove: Breather Hose [C] D r a i nH o s e[ D ] • Insert a minus screw driver [E] into the slit on the joint lock. • T urn the driver to disconnect the joint look. • Pull [B] the fuel outlet hose joint [A] out of the fuel [...]

FUEL SYSTEM (DFI) 3-1 15 Fuel T ank • Check the trim [A] is i n place on the fuel tank. If the trim is damaged or deteriorated, replace i t with a new one. (For KLX250S9 SB/V9 VB models) • Install the fuel tank temporarily . • T ighten the left and right mounting bolts of the fuel tank. • T o measure the gap [A], insert the thickness gauge [...]

3-1 16 FUEL SYSTEM ( DFI) Fuel T ank • Push and pull [B] the hose joint [A] back and forth more than two times, and make sure it is locked and does not come off. WA R N I N G 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. If it comes off, reinstall the[...]

FUEL SYSTEM (DFI) 3-1 17 Evaporative Emission Control System (SEA an d TH Models) The Evaporative Emission Cont rol System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when th e engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the interv[...]

3-1 18 FUEL SYSTEM ( DFI) Evaporative Emission Control System (SEA and TH Models) Separator Operation Test WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any ap[...]

COOLING SYSTEM 4-1 4 Cooling System T able of Contents Exploded View ................................................................................................................... ..... 4-2 Coolant Flow Chart ............................................................................................................... .. 4-4 Specifications ..[...]

4-2 COOLING SYSTEM Exploded View[...]

COOLING SYSTEM 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Radiator Hose Clamp Screws 1.5 0.15 13 in·lb 2 Radiator Fan Bolts 7.0 0.71 62 in·lb L 3 W ater Pump Impeller Nut 7.8 0.80 69 in·lb 4 Thermostat Housing Bolts 9.8 1.0 87 in·lb L 5 W ater Pump Cover Bolts 9.8 1.0 87 in·lb 6 Coolant Drain Plug 25 2.5 18 7 Radiator [...]

4-4 COOLING SYSTEM Coolant Flow Chart[...]

COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiators 2. W ater Hose 3. Thermostat 4. Cylinder Head Jacket 5. Cylinder Jacket 6. Reserve T ank Hose 7. Reserve T ank 8. Reserve T ank Over Flow Hose 9. W ater Pump 10. Radiator Fan 1 1. Cold Coolant 12. W arm Coolant 13. Hot C oolant Permanent type antifreeze (for aluminum radiators) is used as a coolant[...]

4-6 COOLING SYSTEM Specifications Fastener Standard Coolant T ype (Recommended) Permanent T y pe of Antifreeze (Ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50% and coolant 50% Freezing Point 35°C ( 31°F) T otal Amount 1.3 L (1.4 US qt) (reserve tank full level [...]

COOLING SYSTEM 4-7 Special T ools Bearing Driv er Set: 57001-1 129 Bearing Remover Shaft: 57001-1265 Bearing Remover Head 10 × 12: 57001-1266[...]

4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side cover (see Side Cover Removal in the Frame chapter). • Visually in spect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron parts are rusting. In either [...]

COOLING SYSTEM 4-9 Coolant 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 accumulations is not removed, it will clog up the water passage and considerably reduce the ef- ficienc[...]

4-10 COOLING SYSTEM Wa t e r P u m p Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Loosen the clamp screws [A] fully . • Disconnect the radiator hose [B] from the water pump cover [C]. • Remove: W ater P ump Cover Bolts [D] W ater Pump Cover • Remove: Impeller Nut [A] Impeller [B] Water[...]

COOLING SYSTEM 4-1 1 Wa t e r P u m p Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the right engine cover for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one. • Visually check the impeller [A]. If[...]

4-12 COOLING SYSTEM Wa t e r P u m p Ball Bearing, Oil Seal Replacement Although a small quantity of coolant may leak from the mechanical seal until its sealing surface settles, if the leakage still continue, the damages on the seal and the ball bearing are considered. Replace the mechanical seal, ball bearing and oil seal. • Remove the right eng[...]

COOLING SYSTEM 4-13 Wa t e r P u m p • Clean both sliding surfaces of a new mechanical seal with a high-flash point solvent (e.g. ethyl alcohol), and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication. • Apply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and press the rubber sea[...]

4-14 COOLING SYSTEM Radiators Radiator Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Radiator Shrouds (see Radiator Shroud Removal in the Frame chapter) Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Radiator Fan Connector [A] (disconnect) • Loosen the radiator hose clamp[...]

COOLING SYSTEM 4-15 Radiators • Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Installation • Hold the clutch cable with the clamps [A]. • Run the radiator hose and reserve tank hose correctly (see Cable, Wire and Hose Routing in the Appendix chap- ter). T orque - Radiator Bolts : 6.9 N·m (0.70 kgf·m, 61 i n·lb) Radiator Inspecti[...]

4-16 COOLING SYSTEM Radiators Radiator Cap Inspection • Remove the radiator cap. • Visua lly inspect the condition of the bottom [A] and top [B] of the valve seals and valve spring [C]. If they show any damage, replace the cap with a new one. • Install the cap [A] on a pressure tester [B], and check the relief pressure. Apply water or coolant[...]

COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Thermostat Housing Bolts [A] Thermostat Housing [B] • T ake off the thermostat [A] from th e cylinder head. Thermostat Installation • Install the thermostat in the cylinder head so that the air bleeder ho[...]

4-18 COOLING SYSTEM Hose Hose Installation • Install the hoses, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). • Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitti[...]

COOLING SYSTEM 4-19 W ater T emperature Sensor Water T emperature Sensor Removal/Installation • Refer to the W ater T emperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter . Water T emperature Sensor Inspection • Refer to the W ater T emperature Sensor Inspection in the Electrical System chapter .[...]

[...]

ENGINE TOP END 5-1 5 Engine T op End T able of Contents Exploded View ................................... 5-2 Exhaust System Identification ........... 5-6 Specifications .................................... 5-7 Special T ools and Sealants ............... 5-9 Clean Air system ............................... 5-12 Air Suction V alve Removal .........[...]

5-2 ENGINE TOP END Exploded View[...]

ENGINE TOP END 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Cylinder Head Cover Bolts 7.8 0.80 69 in· lb 2 Air Suction V alve Cover Bolts 9.8 1.0 87 in·lb L 3 Camshaft Cap Bolts 12 1.2 106 in·lb S, MO 4 Throttle Body Assy Holder Bolts 12 1.2 106 in·lb 5 Cylinder Head Bolts (M6) 12 1.2 106 in·lb S Cylinder Head Bolts (M10[...]

5-4 ENGINE TOP END Exploded View[...]

ENGINE TOP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Camshaft Sprocket Bolts 9.8 1.0 87 in·lb L 2 Camshaft Chain T ensioner Bolts 9.8 1.0 87 in·lb 3 Camshaft Chain Sub-tensioner Bolt 15 1.5 11 4 Camshaft Chain Guide Bolt 25 2.5 18 5 Camshaft Chain Guide Retaining Plate Bolt 9.8 1.0 87 in·lb 6 Muffler Body Bolts (Fro[...]

5-6 ENGINE TOP END Exhaust Syste m Identification Exhaust Pipe Mark Position [A] Muffler Body Mark Position [B] Honeycomb T ype Catalyst Position[C][...]

ENGINE TOP END 5-7 Specifications Fastener Standard Service Limit Camshaft Cam Height: Exhaust 36.246 ∼ 36.354 mm (1.4270 ∼ 1.4312 in.) 36.15 mm (1.423 in.) Inlet 36.246 ∼ 36.354 mm (1.4270 ∼ 1.4312 in.) 36.15 mm (1.423 in.) Camshaft/Cap Clearance 0.020 ∼ 0.062 mm (0.00079 ∼ 0.0024 in.) 0.15 mm (0.0059 in.) Camshaft Journal Diameter 22.[...]

5-8 ENGINE TOP END Specifications Fastener Standard Service Limit V alve Spring Free Length: Outer (EX, IN) 41.4 mm (1.63 in.) 39.6 mm (1.56 in.) Inner (EX, IN) 36.5 mm (1.44 in.) 34.8 mm (1.37 in.) Cylinder , Piston Cylinder Inside Diameter 72.000 ∼ 72.012 mm (2.8346 ∼ 2.8351 in.) 72.07 mm (2.837 in.) Piston Outside Diameter 71.950 ∼ 71.965 [...]

ENGINE TOP END 5-9 Special T ools and Sealants Compression Gauge 20 k gf/cm²: 57001-221 V alve Spring Compressor Assembly: 57001-241 Piston Pin Puller A ssembly: 57001-910 Piston Ring Compressor Gr ip : 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097 V alve Seat Cutter , 45° - 24.5: 57001-1 1 13 V alve Seat Cutter , 45° - 27.5: 57001-1[...]

5-10 ENGINE TOP END Special T ools and Sealants V alve Seat Cutter H older Bar: 57001-1 128 S p a r kP l u gW r e n c h ,H e x1 6 : 57001-1262 Compression Gauge Adapter M10 × 1.0: 57001-1317 V alve Seat Cutter , 60° - 25: 57001-1328 V alve Seat Cutter Holder , 4.5: 57001-1330 V alve Guide Arbor 4.5: 57001-1331 V alve Guide Reamer 4.5: 57001-1333 [...]

ENGINE T OP END 5-1 1 Special T ools and Sealants V alve Guide Driver At tachment F: 57001-1722 Liquid Gasket, TB1216B: 92104-1064 Liquid Gasket, TB121 1: 56019-120[...]

5-12 ENGINE TOP END Clean Air system Air Suction V alve R emoval • Remove: Air Suction V alve Cover Bolts [A] Air Suction V alve Cover [B] Air Suction V alve [C] Air Suction V alve Installation • Replace the gaskets with new ones. • Install a gasket in such a manner that the 5 mm (0.20 in.) side [A] faces downward [C]. 6 mm (0.24 in.) [B] •[...]

ENGINE T OP END 5-13 Clean Air system Air Switching V alve Inspection • Refer to the Air Switching V alve Unit T est in the Electrical System chapter . Clean Air System Hoses Inspection • Remove the left radiator shroud (see Radiator Shroud Re- move in the Frame chapter). • Air switching valve hose [A] is detached by fitting part [B] in the m[...]

5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Remo val • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) Heat Guard [A] Cylinder Head Cover Bolts [B] • While pushing the right radiator forward, remove the cylin- der head cover [A] from the left side. Cylinder Head Cove r Installation • Replace the cy[...]

ENGINE T OP END 5-15 Camshaft Chain T ensioner Camshaft Chain T ensioner 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. When removing the tensioner , do not take out the mounting bolts only halfway . Retightening the mountin[...]

5-16 ENGINE TOP END Camshaft Chain T ensioner • Install the spring [A] and washer [B]. • T ighten the tensioner cap bolt [C] securely . • Replace the O-ring [A] with a new one. • Install the spring [B]. • T ighten: T orque - Camshaft Chain Sub-t ensioner Bolt [ C]: 15 N·m (1.5 kgf·m, 1 1 ft·lb) The washer [D] is placed between the sub-[...]

ENGINE T OP END 5-17 Camshaft Camshaft Removal • Remove the timing inspection cap [A] and alternator rotor bolt cap [B]. Special T ool - Filler Cap Driver: 57001-1454 • T urn the crankshaft counterclockwise [A] and align the “T” mark line [B] of the rotor with the notch [C] of the alternator cover . • Remove: Cylinder Head Cover (see Cyli[...]

5-18 ENGINE TOP END Camshaft Camshaft Installation Sprockets are the same for both inlet and exhaust sides. • Install the sprocket on the camshaft so that the marked side faces out. NOTE Install sprockets to the camshafts with a sprocket aligned with the IN mark [A] for the inlet side camshaft [B] and the other , with the EX mark [C] for the exha[...]

ENGINE T OP END 5-19 Camshaft 1st Pin [A] 2nd Pin [B] 32th Pin [C] EX Mark [D] IN Mark [E] Cylinder Head Upper Surface [F] Front [G] • Be sure to install the dowel pins [A]. • Be sure to no damage on the c hain guide [A]. If chain guide is damaged, replace it with a new one.[...]

5-20 ENGINE TOP END Camshaft • Install the camshaft cap. • Apply molybdenum disulfide oil to the threads and seating surface of the camshaft cap bolt. • T ighten the camshaft cap bolts. Longer Bolts [A] Front [B] NOTE First gradually tighten the bolt (1) and (2) evenly to seat the camshaft in place, then tighten all bolts following the specif[...]

ENGINE T OP END 5-21 Camshaft KACR (Kawasaki Automa tic Compression Release) Inspection KACR [B] is installed on the left end of the exhaust camshaft [A]. Do not remove or disassemble KACR alone. Since KACR is the simple construction, it does not re- quire periodic maintenance. The KACR mechanism may develop two types of failures. They are failing [...]

5-22 ENGINE TOP END Camshaft Camshaft/Camshaft Cap Wear • Cut the strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. • Measure each clearance between the camshaft and the camshaft cap using plastigage [A]. • Install the camshaft cap (see Camshaft Installation). NOTE[...]

ENGINE T OP END 5-23 Camshaft Cam Wear • Remove the camshaft (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer . If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: Inlet 36.246 36.354 mm (1.42 70 1.4312 in.) Exhaust 36.246 36.354 mm (1. 4270 1.4312 in.) Service Lim it: Inlet[...]

5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE Use the battery which is fully charged. • W arm up the engine thoroughly . • Stop the engine. • Remove: Right and Left Radiator Shrouds Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) • Remove the spark plug with the spark plug wrench. Special T ool[...]

ENGINE T OP END 5-25 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problems Diagnosis Required Action Carbon buildup on piston or in combustion chamber possibly due to damaged valve stem, valve guide stem oil seal and/or damaged piston oil rings. Remove the carbon depos[...]

5-26 ENGINE TOP END Cylinder Head • Remove the hose [A] from air suction valve cover . • Remove the front chain guide [A]. • Remove the cylinder head bolts in the following se- quence: (1) M6 Bolts [B] (2) M10 Allen Bolts [C] • Remove the cylinder head [A]. NOTE If it is hard to remove it, tap lightly using a plastic-faced mallet [B]. Cylin[...]

ENGINE T OP END 5-27 Cylinder Head • Apply a molybdenum disulfied grease to both surfaces and threads of the cylinder head bolts (M10) washers. • T emporarily tighten the cylinder head bolts (M10) and tighten them with specified torque in accordance with the sequence numbers [1 to 4]. T orque - Cylind er He ad Bolt s (M10) : (First) 15 N·m (1 [...]

5-28 ENGINE TOP END Va l v e V alve Removal • Remove the cylinder head. • Remove the valve lifter and shim from the valve. Record the positions of the shims so they can be installed in their original positions. • Compress the valve spring, and remove the split keeper . Special T ools - V alve Spring Compressor Assembly: 57001 -241 [A] V alve [...]

ENGINE T OP END 5-29 Va l v e V alve Guide Installation • Apply a thin coat of 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 and heat the oil. • Using the valv[...]

5-30 ENGINE TOP END Va l v e V alve Seat Ins pection • Remove the valve. • Check the valve seat surface [A] between the valve [B] and valve seat [C]. • Measure the outside diameter [D] of the seating pattern on the valve seat with a pair of vernier caliper . If the outside diameter is too large or too small, repair the seat. V alve Sea t Surf[...]

ENGINE T OP END 5-31 Va l v e Seat Cutter Operating Cares 1. This valve seat cutter is designed only for valve seat repair . Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter , or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the se[...]

5-32 ENGINE TOP END Va l v e T o make the 32° grind, fit a 32° cutter into the holder , and slide it into the valve guide. T urn 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 overgrindin[...]

ENGINE T OP END 5-33 Va l v e V alve Seat Repair[...]

5-34 ENGINE TOP END Cylinder , P iston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Radiator Hose Fitting Bolts [A] Radiator Hose Fitting [B] • Remove the cylinder [A] and cylinder base gasket. NOTE If it is hard to remove it, tap lightly using a plastic-faced mallet [B]. Piston Removal • Remove the cylinder (see Cylin[...]

ENGINE T OP END 5-35 Cylinder , Piston Cylinder , Piston Installation NOTE The oil ring rails have n o “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, one above the expander and one below it. Spread the rail with your thumbs, but [...]

5-36 ENGINE TOP END Cylinder , P iston • Apply liquid gasket to the upper su rface [A] of the crankcase mating surface. [B] about 10 mm (0.39 in.) Sealant - Liquid Gasket, TB1216B: 92104-1064 • Install the dowel pins [A]. • Replace the cylinder base gasket [B] with a n ew one. • Compress the piston ring with fingers or a tool to fit the pis[...]

ENGINE T OP END 5-37 Cylinder , Piston Piston Wear • Measure the outside diameter [A] of each piston 5 mm [B] up from the bottom of the piston at a right angle to the direction of the piston pin. Piston Diameter Standard: 71.950 71.965 mm (2.8327 2.83 33 in.) Service Lim it: 71.80 mm ( 2.827 in .) If the measurement is under the service limit, re[...]

5-38 ENGINE TOP END Cylinder , P iston Piston Ring Groove Width • Measure the width of the top ring [A], second ring [B] and oil ring [C] grooves. Use vernier calipers at several points around the piston. Piston Ring Groove Width Standard: To p 1.02 1.04 mm (0.0402 0.0409 in .) Second 1.02 1.04 mm (0.0402 0.040 9 in.) Oil 2.01 2. 03 mm (0.0791 0.[...]

ENGINE T OP END 5-39 Cylinder , Piston Piston Ring End Gap • 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: T[...]

5-40 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Throttle Body Assy Holder Bolts [A] Throttle Body Assy Holder [B] Throttle Body Assy Holder Installation • Replace the O-ring [A] with a new one. • Apply grease to the O[...]

ENGINE T OP END 5-41 Mufflers Muffler Body Removal WA R N I N G The exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. • Remove: Seat (see Seat Removal in the Frame chapter) Oxygen Sensor Connector [A] • Pull out the turn sig[...]

5-42 ENGINE TOP END Mufflers • Face the clamp bolt [B] on the muffler clamp [A], and po- sition the clamp between the slits [C] on the exhaust pipe [D]. • Install the muffler clamp [A] as shown, and tighten the clamp bolt securely . 20 ∼ 40° [B] • Apply a molybdenum disulfide grease to lower muffler cover bolts [A]. • T ighten: T orque -[...]

CLUTCH 6-1 6 Clutch T able of Contents Exploded View ................................................................................................................... ..... 6-2 Specifications ............................................................................................... .......................... 6-4 Special T ool ...............[...]

6-2 CLUTCH Exploded View[...]

CLUTCH 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Clutch Spring Bolts 7.8 0.80 69 in·lb 2 Clutch Cover Damper Plate Bolts 7.8 0.80 69 in·lb L 3 Clutch Cover Bolts 9.8 1.0 87 in·lb 4 Clutch Cable Holder Bracket Bolts 9.8 1.0 87 in·lb 5 Right Engine Cover Bolts 9.8 1.0 87 in·lb L( 1 ) 6 Oil Seal Retaining Plate B olt 12 [...]

6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Clutch Lever Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Clutch Plate Assy Thickness 30.3 ∼ 30.9 mm (1.19 ∼ 1.22 in.) ––– Clutch Spring Free Length 35.4 mm (1.39 in.) 33.9 mm (1.33 in.) Friction Plate Thickness 2.92 ∼ 3.08 mm (0.1 15 ∼ 0.121 in.) 2.7 mm (0.1 1 in.) F[...]

CLUTCH 6-5 Special T ool Gear Holder: 57001-1602[...]

6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Pla y Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter . Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter . Clutch Cable Removal • Slide the dust cover [A] at the middle of the clutch cab[...]

CLUTCH 6-7 Clutch Cover and Right Engine Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Clutch Cable Lower End (see Clutch Cable Removal) Clutch Cover Bolts [A] Clutch Cover [B] NOTICE Do not remove the clutch release shaft [A] unless it is absolutely necessary . If rem[...]

6-8 CLUTCH Clutch Cover and Right Engine Cover • Remove the rear brake light switch bracket bolt [A] to free the brake light switch. • Remove: Right Front Footpeg Bolt [A] Right Front Footpeg Nut [B] Right Front Footpeg [C] • Remove: Oil Pipe Banjo Bolt [A] • Remove the right engine cover bolts [B] and take off the right engine cover [C] wi[...]

CLUTCH 6-9 Clutch Cover and Right Engine Cover • Apply a non parmanent locking agent to the thread of the right engine cover bolt [A]. • Install the right engine cover . T orque - Right Engine Cover Bolts [ A] [B]: 9.8 N· m (1.0 kgf·m, 87 in·lb) • Install the water pump (see W ater Pump Installation in the Cooling System chapter). • Repl[...]

6-10 CLUT CH Clutch Clutch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Engine Cover (see Right Engine Cover Removal). Oil Pump (see Oil Pump Removal in the Engine Lubri- cation System chapter). • Remove: Clutch Pusher [A] W asher [B] Holder [C] • Using the gear holder [A] to [...]

CLUTCH 6- 1 1 Clutch • Apply molybdenum disulfide grease to the sleeve and in- side of the clutch housing boss. • Install the sleeve [A] into the clutch housing [B]. • Install: Clutch Housing with the sleeve installed W asher [C] • Install the clutch plate assy [A]. Install the last friction plate [B] in the shallower groove in the clutch h[...]

6-12 CLUT CH Clutch • Assemble the friction plate and the clutch plate to the clutch hub. First, install the friction plate [A] and steel plate (without knurling) [B]. Then install the friction plates [C] and steel plates [D] (with knurling), starting with a friction plate and alternating them. T urn the outside friction plate to shift its phase [...]

CLUTCH 6-13 Clutch Friction and Steel Pla tes Wear , Damage Inspection NOTICE If new friction plates are installed, apply engine oil to the surfaces of each plate to avoid seizure. • Visually inspect the frictio n or steel plates for signs of seizure, overheating (discoloration) or uneven wear . Replace any damaged plates. • Measure the thickne[...]

6-14 CLUT CH Clutch Clutch Housing Groove Inspection • Visually inspect the grooves [A] of the clutch housing where the tangs [B] of the friction plates hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged. • Measure the clearance [C] [...]

ENGINE LUBRICA TION SYSTEM 7-1 7 Engine Lubrication System T able of Contents Exploded View ................................................................................................................... ..... 7-2 Engine Oil Flow Chart............................................................................................................. 7[...]

7-2 ENGINE LUBRICA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Oil Pump Mounting Screws 5.2 0.53 46 in·lb 2 Oil Pipe Banjo Bolts (M8) 9.8 1.0 87 in·lb 3 Oil Pipe Banjo Bolt (M10) 20 2.0 15 4 Oil Pump Cover Screws 10 1.0 88 in·lb 5 Engine Oil Drain Plug 15 1.5 11 6 Oil Pressure Relief V alve 15 1.5 11 L EO: Apply e[...]

7-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart[...]

ENGINE LUBRICA TION SYSTEM 7-5 Engine Oil Flow Chart : Oil Flow 1. Camshaft 2. Crankshaft 3. Driveshaft 4. Output shaft 5. Oil Screens 6. Oil Pump 7. Oil filter 8. Camshaft Chain[...]

7-6 ENGINE LUBRICA TION SYSTEM Specifications Item Standard Engine Oil Ty p e AP I SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Vis c o si t y SAE 10W-40 Capacity 1.0 L (1.1 US qt) (when filter is not removed) 1.1 L (1.2 US qt) (when filter is removed) 1.3 L (1.4 US qt) (when engine is completely disassembled and dry) Level Between upper and lower[...]

ENGINE LUBRICA TION SYSTEM 7-7 Special T ools Oil Pressure Gauge, 5 kgf/cm² : 57001-125 Oil Pressure Gauge Adapt er , M10 × 1.25: 57001-1 182 Oil Pressure Cap, M 10 × 1.25: 57001-1361[...]

7-8 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter WA R N I N G V ehicle 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. Oil L[...]

ENGINE LUBRICA TION SYSTEM 7-9 Engine Oil and Oil Filter Oil Screen Removal • Remove the right engine cover (see Right Engine Cover Removal in the Clutch chapter). • Pull the oil screen [A] out of the crankcase. • W ash the oil screen with a high-flash point solvent. WA R N I N G Gasoline and low-flash point solvents can be flammable and/or e[...]

7-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Screws [A] Oil Pump [B] Oil Pump Installation • Install the dowel pins [A] a nd O-ring [B] into the crankcase. • Install the oil pump. • T ighten: T orque - Oil Pump Mounting Screws [A]: 5.2 N·m (0.5[...]

ENGINE LUBRICA TION SYSTEM 7-1 1 Oil Pump Oil Pump Assembly • Apply engine oil to the inner and outer rotors. • Install the following parts to the oil pump body [A]. Outer Rotor [B] Inner Rotor [C] • Replace the circlip [A] with a new one. • Install: Oil Pump Gear [B] Oil Pump Cover [C] W asher [D] Circlip • T ighten: T orque - Oil Pump C[...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pipe Oil Pipe Removal • Remove the starter motor (see Starter Motor Removal in the Electrical System chapter). • Remove the oil pipe banjo bolt [A] provided on the right engine cover side. • Remove the banjo bolts [A] on the cylinder head and crankcase sides and take out the oil pipe. • Remove the oil pip[...]

ENGINE LUBRICA TION SYSTEM 7-13 Oil Pressure Oil Pressure Measure ment • Remove the oil filter cover . • Install the O-ring to the oil pressure cap. • Install the oil pressure cap [A]. Align the oil passage holes of the oil pressure cap and right engine cover . • Install the oil pressure gauge adapter [B] and oil pressure gauge [C]. Special[...]

7-14 ENGINE LUBRICA TION SYSTEM Oil Pressure • Check to see if the steel ball [A] inside the v alve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to original position by valve spring pressure [B]. NOTE Since the relief valve cannot be disassembled, inspect it as an assy . If the steel ball does not m[...]

ENGINE REMOV AL/INST A LLA TION 8-1 8 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 8-2 Special T ool ...............................................................................................................[...]

8-2 ENGINE REMOV AL/INST ALLA TION Exploded View[...]

ENGINE REMOV AL/INST ALLA TION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Engine Mounting Bolt and Nut 50 5.1 37 R, S 2 Upper Engine Bracket Bolts 23 2.3 17 S 3 Lower Engine Mounting Bolt and Nut 50 5.1 37 R, S 4 Front Engine Mounting Bolt and Nut 50 5.1 37 R, S 5 Front Engine Bracket Bolts and Nuts 50 5.1 37 R, S 6 S[...]

8-4 ENGINE REMOV AL/INST ALLA TION Special T ool Jack: 57001-1238[...]

ENGINE REMOV AL/INST ALLA TION 8-5 Engine Removal/Installation Engine Removal • Place a jack [A] under the frame to raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 WA R N I N G Since the swingarm pivot shaft also serves as the engine mounting bolt, removing it may cause the motorcycle to fall over and cause injury . When rem[...]

8-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Right Front Footpeg Bracket Nut [A] Right Front Footpeg Bracket Bolt [B] Right Front Footpeg [C] Brake Light Switch Spring [D] Brake Pedal Return Spring [E] Rear Master Cylinder Mounting Screws [F] • Remove: Bolt [A] • T ake out the rear brake light switch from the frame[...]

ENGINE REMOV AL/INST ALLA TION 8-7 Engine Removal/Installation • Remove: Upper Engine Mounting Bolt [A] and Nut Upper Engine Bracket Bolts [B] Upper Engine Bracket [C] • Remove: Front Engine Mounting Bolt and Nut [A] Front Engine Bracket Bolts and Nuts [B] Front Engine Brackets [C] Lower Engine Mounting Bolt and Nut [D] • Remove the swingarm [...]

8-8 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Drive Chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter) • Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter). ?[...]

CRANKSHAFT/TRANSMISSION 9-1 9 Crankshaft/T ransmission T able of Contents Exploded View ................................... 9-2 Specifications .................................... 9-6 Special T ools and Sealant ................. 9-7 Crankcase ......................................... 9-8 Crankcase Disassembly .............. 9-8 Crankcase Assembly .[...]

9-2 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRANSMISSION 9-3 Exploded View To r q u e No. Fastener N·m kgf·m ft·lb Remarks 1 Crankcase Bolts 9.8 1.0 87 in·lb 2 Crankcase Allen Bolts 12 1.2 106 in·lb 3 Shift Drum Bearing Retaining Bolts 9.8 1.0 87 in·lb 4 Shift Shaft Return Spring Pin 37 3.8 27 L 5 Primary Gear Nut 98 10 72 6 T orque Limiter Cover Bolts 9.8 1.0 87 in·lb 7 St[...]

9-4 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRANSMISSION 9-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 External Shift Mechanism Cover Screw 5.2 0.53 46 in·lb 2 External Shift Mechanism Cover B olts 9.8 1.0 87 in·lb 3 Shift Pedal Bolt (KLX250S9 ∼ SB/V9 ∼ VB) 9.8 1.0 87 in·lb 4 Gear Positioning Lever Nut 9.8 1.0 87 in·lb 5 Drive Chain Guard Plate Bolts [...]

9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rod Connecting Rod Bend ––– 0.2 mm (0.008 in.) Connecting Rod T wist ––– 0.2 mm (0.008 in.) Connecting Rod Big End Radial Clearance 0.008 ∼ 0.02 mm (0.0003 ∼ 0.0008 in.) 0.07 mm (0.003 in.) Connecting Rod Big End Side Clearance 0.25 ∼ 0.3[...]

CRANKSHAFT/TRANSMISSION 9-7 Special T ools and Sealant Bearin g Pulle r: 57001-135 Outside C irclip Pliers : 57001-144 Bearing Driv er Set: 57001-1 129 Crankshaft Ji g: 57001-1 174 Grip: 57001-1591 Gear Holder: 57001-1602 Rotor Holder: 57001-1723 Liquid Gasket , TB1216B: 92104-1064[...]

9-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Remo val in the Engine Removal/Installation chapter). • Remove: T orque Limiter (see T orque Limiter Removal) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Oil Pipe (see Oil Pipe Removal in the Engine Lubrica[...]

CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Remove: Crankcase Bolts [A] Allen Bolts [B] • Place it with the left crankcase facing downward. • Pry the points [A] to split the crankcase halves apart, and remove the right crankcase half. • Remove: Balancer [A] Shift Rods [B] Shift Forks [C] Shift Dram [D] T ransmission [E] NOTE T urn the crankshaf[...]

9-10 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Assembly NOTICE The right and left crankcase halves are machined at the factory in the ass embled state, so they must be replaced as a set. • Remove the old gasket from the mat ing surfaces of the crankcase halves, and clean of f the crankcase with a high flash-point solvent. • Using compressed a[...]

CRANKSHAFT/TRANSMISSION 9-1 1 Crankcase • T ighten the retaining bolts [A]. T orque - Shift Drum Bearing Retai ning Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the oil return pipe [B]. • Install the crankshaft (see Crankshaft Installation). • Apply engine oil to the crankcase bearing, transmission gears and bearings, shift drum, shift[...]

9-12 CRANKSHAFT/TRANSMISSION Crankcase • Apply liquid gasket [A] to the mating surfaces of the right crankcase half. Sealant - Liquid Gasket, TB1216B: 92104-1064 NOTE Make the application finish within 20 minutes when the liquid gasket to the mating surface of the crankcase half is applied. Moreover fit the case and tighten the case b olts just a[...]

CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Install the gear positioning lever [A]. Fit the each ends [B] of the spring as shown. Do not forget to install the washer and spacer [C]. • T ighten: T orque - Gear Positioning Lever Nut [ D]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the pin [A] to the shift drum cam [B]. • Install the shift drum c[...]

9-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase, and remove the right crankcase half (see Crankcase Splitting). • Pull out the shift rod, and take of f the shift forks. • Remove the shift drum. • Remove the drive shaft and output shaft. • Remove the balancer . • Using a press [A], remove [...]

CRANKSHAFT/TRANSMISSION 9-15 Crankshaft/Connecting Rods Connecting Rod Bend Ins pection • Select an arbor of the same diameter as the piston pin and more than 100 mm long, and insert the arbor [A] through the connecting rod small end. • Set the journal portions [C] of the crankshaft on V blocks [B]. • With the connecting rod held vertically ,[...]

9-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Runout Inspection • Set the crankshaft in a flywheel arrangement jig or on V blocks, and place a dial gauge as shown. Turn the crank- shaft slowly . The largest dif ference in gauge readings (TIR) for each point is taken as crankshaft runout at that point. 10 mm (0.39 in.) [A] 15 [...]

CRANKSHAFT/TRANSMISSION 9-17 T ransmission Transmission Removal • Split the crankcase (see Crankcase Splitting). • Pull off the shift rods [A], and disengage the shift fork guide pins from the shift drum [B]. • Remove: Shift Forks [C] Shift Drum • T urn the c rankshaft [A] to position where the crankshaft web does not get in the way of the [...]

9-18 CRANKSHAFT/TRANSMISSION T ransmission The shift forks can be identified by their shapes. Driveshaft 3/4th gear shi ft fork [A] ···· Shorter ears Output shaft 6th gear shift f ork [B] ·· ·· Guide pin goes to le ft side of the ears 5th gear s hift fork [C] ···· Guid e pin goes to t he center of th e ears • Assemble the crankcase (s[...]

CRANKSHAFT/TRANSMISSION 9-19 T ransmission 1. W asher ( 28) 2. 2nd Gear (15T) 3. Circlip 4. T oothed Washer ( 27) 5. 6th Gear (21T) 6. 3rd/4th Gear (18T/20T) 7. W asher ( 27) 8. 5th Gear (20T) 9. 1st Gear (10T) 10. Drive Shaft 1 1. W asher ( 28) 12. 1st Gear (30T) 13. W asher ( 25.5) 14. 5th Gear (21T) 15. Circlip 16. T oothed Washer ( 31) 17. 4th [...]

9-20 CRANKSHAFT/TRANSMISSION T ransmission Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bend. A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear under power . 90° [A] Shift Fork/Gear Groove Wear Inspection • Measure the thickness of the shift fork ears [...]

CRANKSHAFT/TRANSMISSION 9-21 Starter Motor Clutch/T orque Limiter Starter Motor Clutch Re moval/Installation • Refer to the Alternator Rotor Removal and Insta llation in the Electrical System chapter . Starter Motor Clutch Disassembly • Remove the alternator rotor (see Alternator Rotor Re- moval in the Electrical System chapter). • Unscrew th[...]

9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch/T orque Limiter • Remove the torque limiter [A]. There are washers set on both sides of the torque limiter . T orque Limiter Inspection • Remove the torque limiter [A] (see T orque Limiter Re- moval) and visually inspect it. If the limiter has wear , discoloration, or damage, replace it. T orque[...]

CRANKSHAFT/TRANSMISSION 9-23 Primary Gear Primary Gear Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Oil Pump (see Oil Pump Removal in the Engine Lubri- cation System chapter) • Loosen the clutch hub nut [A] (see Clutch Removal in the Clutch chapter). • Remove the primary gear nut [B]. • Remove [...]

9-24 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove the balancer from the left crankcase with the punch marks [A] provided on the balancer gear [B] and the driven gear [C] of the cranksha ft aligned with each other . Balancer Disassembly • Remove the balancer gear [A] from the balan[...]

CRANKSHAFT/TRANSMISSION 9-25 External Shift Mechanism Shift Pedal Removal • Unscrew the mounting bolts [A] and remove the shift pedal [B]. Shift Pedal Installation • Install the shift pedal, and tighten the mounting bolt. T orque - Shift Pedal Bolt (KLX250S9 SB/V9 VB): 9.8 N·m (1.0 kgf·m , 87 in·lb ) Shift Pedal Bolt ( KLX250SC/VC): 12 N· m[...]

9-26 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Set the shift mechanism cover [A] to the shift shaft as shown. • While pushing the shift mechanism lever [B] backward, pull out the shift shaft [C] to remove the shift mechanism cover together with the shift shaft assembly . • Remove: Shift Drum Cam Holder Bolt [A] Shift Drum Cam Holder [...]

CRANKSHAFT/TRANSMISSION 9-27 External Shift Mechanism • Install the pin [A]. • Use a screw driver to push down the gear positioning lever [B] and set the shift drum cam [C] so that the groove [D] of the shift drum cam fit the pin. • Install the pin [A] to the s hift drum cam. • Install the shift drum cam holder [B] s o that the groove [C] o[...]

9-28 CRANKSHAFT/TRANSMISSION External Shift Mechanism External Shift Mechanism Inspection • Inspect the shift shaft [A] for any damage. If the shaft is bent, repair or replace it. If the spring [B] or shift pedal return spring [C] are dam- aged, replace the spring. If the shift mechanism arm [D] is damaged, replace the assembly . • Check that t[...]

CRANKSHAFT/TRANSMISSION 9-29 Bearing, Oil seal Bearing Replacement NOTICE Do not remove the ball bearings unless it is neces- sary . Removal may damage them. • Using a press or puller , remove the ball bearing. NOTE In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to ap- proximately 93°C (20[...]

[...]

WHEELS/TIRES 10-1 10 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ............................................................................................... .......................... 10-4 Special T oo[...]

10-2 WHEELS/TIRES Exploded View[...]

WHEELS/TIRES 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Spoke Nipples 4.0 0.41 35 in·lb 2 Front Axle Clamp Bolts 20 2.0 15 AL, S 3 Front Axle Nut 88 9.0 65 S 4 Rear Axle Nut 11 0 11 . 2 81.1 R 5. BR and EUR Models 6. KLX250S Model 7. KLX250V Model AL: T ighten the two clamp bolts alternately two times to ensure even tight[...]

10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial: KLX250S TIR 0.7 mm (0.028 in.) or less TIR 2.0 mm (0.08 in.) KLX250V TIR 0.8 mm (0.031 in.) or less TIR 2.0 mm (0.08 in.) Radial: KLX250S TIR 1.0 mm (0.039 in.) or less TIR 2.0 mm (0.08 in.) KLX250V TIR 1.2 mm (0.047 in.) or less TIR 2.0 mm (0.08 in.) Axle[...]

WHEELS/TIRES 10-5 Specifications W A RNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. T o ensure p roper handling and stability , use only the recommended standard tires for replacement, inflated to the standard pressure.[...]

10-6 WHEELS/TIRES Special T ools Inside Circl ip Pliers: 57001-143 Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Bearing Remover Head, 15 × 17: 57001-1267 Bearing Remover Head, 20 × 22: 57001-1293 Bearing Remover Shaft, 13: 57001-1377[...]

WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Removal • Remove the front axle nut cap (EUR model). • Remove the front axle nut [A]. • Remove the front axle clamp bolts [B]. • Raise the front wheel off the ground with jack. Special T ool - Jack: 57001-1238 • Pull out the axle to the right and drop the front wheel out of the forks. NOTICE Do [...]

10-8 WHEELS/TIRES Wheels (Rims) • Pump the front fork up and down [A] 4 or 5 times to all on the right front fork leg to seat on the front axle before tightening the front axle clamp bolts. NOTE Do not stop motorcycle moving forward with the front brake. Put a block [B] in front of the front wheel to stop moving. • T ighten: T orque - Front Axl[...]

WHEELS/TIRES 10-9 Wheels (Rims) • Squeeze the front brake lever , and hold it with a band [A] to prevent the motorcycle from running forward. WA R N I N G Motorcycle may fall over unexpectedly resulting in an accident or injury . Be sure to hold the front brake when removing the rear wheel. • Remove: Rear Axle Nut [A] W asher [B] Adjuster [C] ?[...]

10-10 WHEELS/TIRES Wheels (Rims) • Install the caliper bracket [A] with the caliper installed onto the stopper rail [B] of the swingarm. • Engage the drive chain with the rear sprocket. • Insert the axle from the left side of the wheel. • Replace the rear axle nut with a new one. • Adjust the drive chain slack before tightening the axle n[...]

WHEELS/TIRES 10-1 1 Wheels (Rims) Rim Inspection • Refer to the Spoke T ightness and Rim Runout Inspection in the Periodic Maintenance 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] shoul[...]

10-12 WHEELS/TIRES Ti r e s Air Pressure Inspectio n/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter . Ti re I n s p e c t i o n • Refer to the Wheel/T ire Damage Inspection in the Peri- odic Maintenance chapter . Ti re R e m o v a l • Remove the wheel (see Front/Rear Wheel Removal). NOTICE Do not lay t[...]

WHEELS/TIRES 10-13 Ti r e s • Step on the side of the tire opposite air valve, and pry the tire off the rim with the tire iron [A] of the bead breaker protecting the rim with rim protectors [B]. Special T ools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 NOTICE T ake care not to insert the tire irons so deeply that the tube gets [...]

10-14 WHEELS/TIRES Ti r e s • T ighten the valve stem nut [A], and put on the valve cap [B]. Adjust the tire air pressure to the specified pressure (see Air Pressure Inspection in the Periodic Maintenance chapter).[...]

WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Front Grease Seal [A] Circlip [B] Special T ool - Inside Circlip Pliers: 57001-143 Rear Grease Seals [A] Circlip [B] Special T ool - Inside Circlip Pliers: 57001-143 • Use the bearing remover to remove the hub bearin[...]

10-16 WHEELS/TIRES Hub Bearing 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. • Install the hub front bearings in the following sequence. Press in the left side bearing [A] until[...]

FINAL DRIVE 1 1-1 11 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 1 1-2 Specifications ............................................................................................... .................. ........ 1 1-4 Special T o[...]

1 1-2 FINAL DRIVE Exploded View[...]

FINAL DRIVE 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb L( 1 ) 2 Rear Sprocket Nuts 32 3.3 24 R 3 Engine Sprocket Nut 125 12.7 92.2 MO 4. Chain Slipper 5. Front Chain Guide 6. Rear Chain Guide 7. Chain Guide Roller 8. BR and EUR Models 9. KLX250V Model G: Apply grease. HO Apply[...]

1 1-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Chain Slack 35 ∼ 45 mm (1.4 ∼ 1.8 in.) ––– 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make ENUMA ––– Ty p e EK520L V-O ––– Link: KLX250S 106 Links ––– KLX250V 104 Links ––– Sprockets Rear Sprocket[...]

FINAL DRIVE 1 1-5 Special T ool Jack: 57001-1238[...]

1 1-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter . Wheel Alignment Inspection/Adjustment • Refer to the Wheel Alignment Inspection in the Perio[...]

FINAL DRIVE 1 1-7 Sprocket Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Chain Guide [C] • Flatten out the bended washer [A]. • Remove: Engine Sprocket Nut [B] W asher NOTE When loosening the engine sprocket nut, hold the rear brake on. • Slack off the drive chain fully . • Remove the engine s[...]

1 1-8 FINAL DRIVE Sprocket • Apply a non-permanent locking agent to the threads of the engine sprocket cover mounting bolt (upper) [A]. • Install the chain guide [B] and engine sprocket cover [C]. T orque - Engine Sprocket Cover Mounting Bolts: 9.8 N·m (1.0 kgf·m , 87 in·lb ) • Adjust the drive chain slack (see Drive Chain Slack Ad- justme[...]

FINAL DRIVE 1 1-9 Sprocket Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with jack so that it will turn freely . Special T ool - Jack: 57001-1238 • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the high[...]

[...]

BRAKES 12-1 12 Brakes T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ............................................................................................... .......................... 12-6 Special T ool ...........[...]

12-2 BRAKES Exploded View[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Brake Light Switch Mounting Screw 1.2 0.12 11 i n · l b 2 Front Master Cylinder Reservoir Cap Screws 1.5 0.15 13 in·lb 3 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si 4 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb 5 Caliper Bleed V alve 7.8 0.80 69 in·lb 6 Fron[...]

12-4 BRAKES Exploded View[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Master Cylinder Reservoir Cap Screws 1.5 0.15 13 in·lb 2 Brake Pad Pin Cap 2.5 0.25 22 in·lb 3 Caliper Blee d V alv e 7.8 0.80 69 in·lb 4 Rear Master Cylinder Mounting Screws 7.8 0.80 69 in·lb 5 Rear Caliper Brake Pad Pin 17 1.7 12 6 Rear Master Cylinder Push Rod L[...]

12-6 BRAKES Specifications Fastener Standard Service Limit Brake Lever , Brake Pedal Brake Lever Free Play Non-adjustable ––– Pedal Free Play Non-adjustable ––– Pedal Position: KLX250S About 0.7 mm (0.03 in.) above top of footpeg ––– KLX250V About 13.4 mm (0.53 in.) below top of footpeg ––– Brake fluid Grade DOT3 or DOT4 –[...]

BRAKES 12-7 Special T ool Jack: 57001-1238[...]

12-8 BRAKES Brake Pedal Brake Pedal Position Inspection • Check that the brake pedal [A] is in the correct position. Footpeg [B] Pedal Positio n Standard: KLX250S [C] About 0.7 mm (0.03 in.) [D] above top of footpeg KLX250V [E] About 13.4 mm (0.53 in.) [F] below top of footpeg If it is incorrect, adjust the brake pedal position. Brake Pedal Posit[...]

BRAKES 12-9 Brake Pedal • Remove: Brake Pedal Return Spring [A] Brake Light Switch Spring [B] Brake Pedal [C] Brake Pedal Installation • Replace O-rings [A] with new ones, and apply grease to the O-rings. • Apply grease to the shaft portion of the brake pedal. • Install the brake pedal onto the frame with the return spring and brake light s[...]

12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the brake hose clamp bolt [B]. • Unscrew the caliper mounting bolts [C], and detach the caliper [D] from the disc. • Unscrew the banjo bolt and remove the brake hose [E] from the caliper (see Brake Hose and[...]

BRAKES 12-1 1 Calipers • Remove the caliper mounting bolt [A] to separate the caliper [B] and caliper bracket [C]. Caliper Installat ion • Install the caliper and brake hose lower end. • Replace the washers on each side of hose fitting with new ones. • Apply silicone grease to the rear caliper mounting bolt. • T ighten: T orque - Calipe r[...]

12-12 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase. • Repl[...]

BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty . Front Caliper [B] Rear Caliper [C] Caliper Hol der Shaft W ear The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not sli[...]

12-14 BRAKES Brake Pads Front Brake Pad Removal • Loosen the pad pins [A]. • Remove the front caliper with the brake hose installed (see Front Caliper Removal). • Remove the pad pins. • Remove the pad [A] of the jaw side. • Remove the pad [B] of the piston side. Front Brake Pad Installation • Push the caliper pistons in by hand as far a[...]

BRAKES 12-15 Brake Pads • Remove: Plug [A] Pad Pin [B] Piston Side Pad [C] Jaw Side Pad [D] Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install the anti-rattle spring in its correct position. • Install the pad on the piston side first, then install the other pad. • T ighten the brake pad pins t[...]

12-16 BRAKES Master Cylinder Front Master Cylinder Re moval • Disconnect the brake hose from the master cylinder (see Brake Hose Replacement in the Periodic Maintenance chapter). • Disconnect the front brake light switch connectors [A]. • Unscrew the clamp bolts [A], and take of f the master cylin- der as an assembly with the reservoir , brak[...]

BRAKES 12-17 Master Cylinder Rear Master Cylinder Removal • Remove: Cotter Pin [A] Joint Pin [B] W asher [C] • Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose and Pipe Replacement in the Peri- odic Maintenance chapter). • Remove: Rear Master Cylinder Mounting Screws [B] Rear Master Cylinder [C] • Slide the res[...]

12-18 BRAKES Master Cylinder Rear Master Cylinder Disassembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter . Master Cylinder Assembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter . Master Cylinder Inspection • Remove the master cylinders (see Front/R[...]

BRAKES 12-19 Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/T ires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. Brake Disc Installation KLX250S Model • Before front brake disc installation, install the damper [A] to the hub so that the projections [B] contact the hub flan[...]

12-20 BRAKES Brake Disc Brake Disc Warp • Raise the wheel off the ground with jack (see Front/Rear Wheel Removal in the Wheels/T ires chapter). Special T ool - Jack: 57001-1238 For front disc inspection, turn the handlebar fully to one side. • Set up a dial gauge against the disc [A] as shown and measure disc runout, while turning [B] the wheel[...]

BRAKES 12-21 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter . Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter . Brake Line Bleeding The brake fluid has a very low compression coef ficient so that almost all the movement of the br[...]

12-22 BRAKES Brake Fluid • Bleed the brake line and the caliper . Repeat this operation until no more air can be seen com- ing out into the 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 hold- ing the brake applied. 3. Release the brake [C]. NOT[...]

BRAKES 12-23 Brake Fluid WA R N I N G 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[...]

12-24 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter . Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter .[...]

SUSPENSION 13-1 13 Suspension T able of Contents Exploded View ................................................................................................................... ..... 13-2 Specifications ............................................................................................... .......................... 13-6 Special T ools ..[...]

13-2 SUSPENSION Exploded View[...]

SUSPENSION 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fork Cylinder V alve Assys 55 5.6 40 L 2 Piston Rod Nuts 15 1.5 11 3 Upper Front Fork Clamp Bolts 20 2.0 15 AL 4 Lower Front Fork Clamp Bolts 25 2.5 18 5 Front Fork T op Plugs 30 3.0 22 6. BR and EUR Models 7. KLX250V Model 8. KLX250S9 (TH)/V9 (TH) AL: T ighten th[...]

13-4 SUSPENSION Exploded View[...]

SUSPENSION 13-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Rear Shock Absorber Bolt 39 4.0 29 2 Lower Rear Shock Absorber Bolt 39 4.0 29 3 T i e-rod Nuts 83 8.5 61 R 4 Swingarm Pivot Shaft Nut 88 9.0 65 5 Rocker Arm Pivot Shaft Nut 98 10 72 6. BR and EUR Models G: Apply grease. R: Replacement Parts[...]

13-6 SUSPENSION Specifications Fastener Standard Service Limit Front Fork Air Pressure Atmospheric Pressure (Non-adjustable) –– – Fork Oil: Vi scosity KHL15-10 (KA Y ABA01) or equivalent Approx. 450 mL (15.2 US oz.) (when changing oil) ––– Amount: KLX250S 531 ± 4 mL (18.0 ± 0.1 US oz.) (after disassembly and completely dry) ––– [...]

SUSPENSION 13-7 Specifications Gas Reservoir Compression Damper Setting (from the seated position adjuster turned fully clockwise) 16 clicks counterclockwise (Adjustable Range) 20 clicks Gas Pressure 980 kPa (10 kgf/cm², 142 psi) ––– Tie -rod, Rocker Arm Sleeve Outside Diameter: 24.987 ∼ 25.000 mm (0.98373 ∼ 0.98425 in.) 24.85 mm (0.9783[...]

13-8 SUSPENSION Special T ools Oil Seal & Bearing Remover: 57001-1058 Hook Wrenc h R37.5, R42: 57001-1 101 Bearing Driver Set: 57001-1 129 Fork Outer T ube Weight: 57001-1218 Jack: 57001-1238 Fork Spring Holder: 57001-1286 Fork Cylinder Holder: 57001-1287 Fork Oil Level Gauge: 57001-1290 Fork Piston Rod Pu ller , M10 × 1.0: 57001-1298 Fork Oil[...]

SUSPENSION 13-9 Front Fork Front Fork Damping Force Adjustment • T urn the adjuster [A] of the front fork cylinder valve with a flat head screw driver to adjust compression damping to a preference condition. NOTICE The left and right fork legs must have the same shock damping. Seated positions adjuster turned fully clockwise [A]. Compression Damp[...]

13-10 SUSPENSION Front Fork Front Fork Installation • Install the front fork so that the distance between the top end [A] of the outer tube and the upper surface [B] of the steering stem head becomes 6 mm (0.24 in.) [C]. • T ighten the lower front fork clamp bolt and top plug. T orque - Lower Front Fork Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·[...]

SUSPENSION 13-1 1 Front Fork • Remove the fork tube from the vise, and drain the fork oil into a suitable container . NOTE T o drain off fork oil, hold the fork tube downward and move the piston rod [A] up and down, more than ten times • Hold the fork tube upright in a vise, press the outer tube [A] and the piston rod all the way down. • Pour[...]

13-12 SUSPENSION Front Fork • Pump the outer tube up and down several times to dis- charge the air between the outer tube and inner tube. • W ait until the oil level stabilizes. • Measure the distance from the top of the inner tube to the fork oil, using the fork oil level gauge [A]. Special T ool - Fork Oil Level Gauge: 57001-1290 With the f[...]

SUSPENSION 13-13 Front Fork Front Fork Disassembly • Drain the fork oil (see Front Fork Oil Change). • Remove: Piston Rod Nut [A] Spring Guide [B] • Hold the outer tube sideways and hold the inner tube in a vice. • Push the outer tube as far as it will go. Hold the cylinder unit [A] with the fork cylinder holder [B], and loosen the cylinder[...]

13-14 SUSPENSION Front Fork Remove the retaining ring [A] from the outer tube. Holding the inner tube [A] by hand, pull the outer tube [B] several times to pull out the outer tube. NOTE If the outer tube does not detach easily , set the fork outer tube weight [A] onto it to separate the inner and outer tubes. Special T ool - Fork Outer T ube Weight[...]

SUSPENSION 13-15 Front Fork • Insert the spring band of the dust seal, dust seal, oil seal, washer and guide bush to the inner tube and set the guide bushing to the inner tube. • When assembling the outer tube guide bushings [A], hold the washer [B] against the guide bushing and tap the washer with the fork oil seal driver [C] until it stops. S[...]

13-16 SUSPENSION Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A], and repair any dam- age. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube. Since damage to the inner tube [...]

SUSPENSION 13-17 Front Fork Guide Bushings Inspection • Visually inspect the guide bushings [A], and replace them if necessary .[...]

13-18 SUSPENSION Rear Shock Absorber Rebound Damping Adjustment • T urn the rebound damping adjuster [A] on the rear shock absorber lower end with a screwdriver until you feel a click. If the damper setting feels too soft or too stiff, adjust it in accordance with the following table. Seated position: adjuster turned fully clockwise [A]. Rebound [...]

SUSPENSION 13-19 Rear Shock Absorber Spring Preload Adjustment • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). • Hold the lower of the rear shock absorber with a v ise. • Using the hook wrenches [A], loosen the locknut [B] and turn the adjusting nut [C] as required. When you turn the adjustment nut upward, initial load w[...]

13-20 SUSPENSION Rear Shock Absorber • Using the available jack [A], lift the rear wheel as shown. • Remove the upper rear shock absorber bolt [A], and re- move the rear shock absorber [B] to the left side. Rear Shock Absorber Installation • Apply grease to the needle bearings and inside of the oil seals. • Replace the tie-rod nut with a ne[...]

SUSPENSION 13-21 Rear Shock Absorber Rear Shock Absorber Scrapping WA R N I N G Pressurized nitrogen may explode when heated. The rear shock contains nitrogen gas. T o avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve. • Remove the shock absorber (see Rear Shock Absorber Remo[...]

13-22 SUSPENSION Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/T ires chapter) Rear Fender Flap Front (see Rear Fender Flap Front Removal in the Frame chapter) T ie-rod Bolt and Nut (Rear) [A] Swingarm Pivot Shaft Nut [B] • Remove: Bolts [A] Chain Guide [B] Bolt [C] and Nuts Chain Slipper [D] • EUR model[...]

SUSPENSION 13-23 Swingarm Swingarm Installation • Install the grease seals [A] so that the hollow side [B] face the sleeve [C] in the swingarm pivot hole. • Apply grease to the needle bearings [D] and outside of the sleeves. • Replace the tie-rod nut with a n ew one. • T ighten: T orque - Swingarm Pivot Shaf t Nut: 88 N·m (9.0 kgf·m, 65 f[...]

13-24 SUSPENSION T ie-rod, Rocker Arm Tie-rod Removal • Using the jack, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Remove: T ie-rod Bolts [A] and Nuts T ie-rod [B] Tie-rod Installation • Install the tie-rods so that the marked side [A] faces out- side. • Replace the tie-rod nuts with new ones. • T ighten: T or[...]

SUSPENSION 13-25 Tie-rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: T ie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm R emoval) Swingarm (See Swingarm Removal) Sleeves [A] Grease Seals [B] Needle Bearings [C] Remove the rocker arm pivot and tie-rod needle bearings, using the oil seal & bearing remover [A]. Special T[...]

13-26 SUSPENSION T ie-rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearings with new ones. • Apply plenty of grease to the new needle bearings. • Install the needle bearings so that the manufacturer ’s marks faces out. • Install the new needle bearings [A] and grease seals [B] position as shown 5.0 mm ([...]

SUSPENSION 13-27 Tie-rod, Rocker Arm Needle Bearing, Sleeve In spection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings in stalled in the rocker arm. The needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually in- spect the bearings for a[...]

[...]

STEERING 14-1 14 Steering T able of Contents Exploded View ................................................................................................................... ..... 14-2 Special T ools ................................................................................................................... ....... 14-4 Steering ...........[...]

14-2 STEERI NG Exploded View[...]

STEERING 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Steering Stem Nut 4.9 0.50 43 in·lb 2 Handlebar Clamp Bolts 25 2.5 18 S 3 Steering Stem Head Nut 44 4.5 32 4 Upper Front Fork Clamp Bolts 20 2.0 15 AL 5 Lower Front Fork Clamp Bolts 25 2.5 18 6 Left Switch Housing Screws 3.5 0.36 31 in·lb 7 Right Switch Housing Screws 3[...]

14-4 STEERI NG Special T ools Bearing Pulle r: 57001-135 Steering Stem Bearing Dr iver: 57001-137 Steering Stem Bearing Drive r Adapter , 34.5 : 57001-1074 Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver , 54.5: 57001-1077 Steering Stem Nut Wrenc h: 57001-1 100 Head Pipe Outer Race Driver , 46.5: 57001-1 106 Head Pipe Outer[...]

STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter . Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter .[...]

14-6 STEERI NG Steering Stem Steering Stem, Stem Bearing R emoval • Disconnect the starter lockout switch connector [A]. • Open the clamp [B]. • Remove the left switch housing [C] from the handlebar . • Remove the clutch cable upper end [D] from the clutch lever . • Disconnect the brake light switch connectors [A]. • Open the clamp [B].[...]

STEERING 14-7 Steering Stem • Remove: Speed Sensor Lead Clamp Bolt [A] Front Wheel (see Front Wheel Removal in the Wheels/T ires chapter) Remove the right fork protector with the speed sensor . • Remove: Steering Stem Head Nut [A] and W asher Upper Front Fork Clamp Bolts [B] Steering Stem Head [C] Lower Front Fork Clamp Bolts [D] • Remove the[...]

14-8 STEERI NG Steering Stem • 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 T ool - H ead Pipe Outer Race Remover ID>37 mm: 57001-1 107 NOTE If either steering stem bearing[...]

STEERING 14-9 Steering Stem • Apply grease to the upper inner race, and install it in the head pipe. • Install the stem through the head pipe and upper bearing, and hand-tighten the nut while pushing up on the stem base. • Install the stem head and washer , and tighten the stem head nut lightly . • Settle the bearing in place as follows; T [...]

14-10 STEERING Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem. Stem Cap Dete rioration, Damage Replace the stem cap if its oil seal [A] shows damage.[...]

STEERING 14-1 1 Handlebar Handlebar Removal • Remove: Left Handlebar Grip [A] Clutch Cable Upper End [B] (see Clutch Cable Removal in the Clutch chapter) Left Switch Housing [C] Clutch Lever Assembly [D] Clamp [E] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- der Removal in the Brakes chapter) Right Switch Housing [B] Throt[...]

14-12 STEERING Handlebar • Install the clutch lever (see Clutch Lever Installation in the Clutch chapter). • Apply adhesive to the inside of the left handlebar grip. • Install the left handlebar grip until its end hit the handlebar end and up mark [A] faces upward. • Install the left switch housing. Fit the spacer [A] into the groove on the[...]

FRAME 15-1 15 Frame T able of Contents Exploded View ................................................................................................................... ..... 15-2 Special T ool .................................................................................................................... ........ 15-5 Seat ....................[...]

15-2 FRAME Exploded View[...]

FRAME 15-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Footpeg Bracket Bolt 39 4.0 29 2 Front Footpeg Bracket Nut 39 4.0 29 R 3 Sidestand Nut 44 4.5 32 R 4 Sidestand Switch Mounting Bolt 8.8 0.90 78 in·lb L 5. KLX250S Model 6. KLX250V and EUR M odels G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement [...]

15-4 FRAME Exploded View 1. KLX250V Model[...]

FRAME 15-5 Special T ool Jack: 57001-1238[...]

15-6 FRAME Seat Seat Removal • Remove: Left and Right Side Covers (see Side Cover Removal) Bolts [A] T andem Belt [B] • Pull the seat [C] backward to remove the seat. Seat Installation • Insert the seat hooks [A] into the stoppers [B] of the fuel tank and the frame.[...]

FRAME 15-7 Side Cover Side Cover Removal • Remove: Bolts [A] Side Cover [B] Side Cover Installation • Fit the notch [A] of the side cover to the tandem belt [B] lower side, and tighten the mounting bolts.[...]

15-8 FRAME Radiator Shroud Radiator Shroud Removal • Remove: Bolts [A] Radiator Shroud [B] Radiator Shroud Installation • Install: Radiator Shroud [A] Bolts (L = 12) [B] Bolt (L = 20) [C][...]

FRAME 15-9 Fender Front Fender Removal • Remove: Bolts [A] Front Fender [B] Front Fender Installation • Installation is the reverse of removal. • Be sure to install the collars [A] to the front fender . Rear Fender Front Removal • Remove: Rear Fender Rear (see Rear Fender Rear Removal) Muffler Body Cover (see Muf fler Body Removal in the En[...]

15-10 FRAME Fender Rear Fender Flap Front Removal • Remove: Bolts [A] • Remove the rear fender flap front [B] from the air cleaner housing. Rear Fender Rear Removal • Remove: Seat (see Seat Removal) T ool Kit Bag (see T ool Kit Bag Removal) • Open the clamp [A]. • Remove: Bolts [A] • Remove: Bolts [A] Rear Fender Rear [B] Rear Fender Re[...]

FRAME 15-1 1 Fender Rear Fender Flap Rear Remo val • Remove: Rear Fender Rear (see Rear Fender Rear Removal) Clamp [A] • Disconnect: T ail/Brake Light Connector [B] T urn Signal Light Connectors [C] • Remove the mounting bolts [D], then remove the rear fender flap rear together with the tail/brake light and turn signal lights installed. • R[...]

15-12 FRAME Battery Case Battery Case Removal • Remove: Battery (see Battery Removal in the Electrical System chapter) Bolts [A] Reserve T ank [B] NOTICE Make sure that the reserve tank will not be put up- side down, or the coolant may leak from the over- flow hose. • Remove: Bolt [A] Screw [B] Nut [C] Battery Case [D] Battery Case Installation[...]

FRAME 15-13 To o l K i t B a g T ool Kit Bag Remova l NOTE Before washing the motorcycle, empty the tool kit bag. • Remove: Bolts [A], Nuts and Collars T ool Kit Bag [B] T ool Kit B ag Installation • Insert the collar [A] into the larger hole. • Install the tool kit bag on the rear fender rear with the short bolts [B] in the front side, the l[...]

15-14 FRAME Sidestand Sidestand Removal • Raise the rear wheel of f the ground with the jack. Special T ool - Jack: 57001-1238 • Remove: Sidestand Switch Mounting Bolt [A] Sidestand Switch Cover [B] Sidestand Switch [C] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation • Apply grease to the slidi[...]

FRAME 15-15 Sidestand • Install the sidestand switch cover [A] as follows. Insert the projections [B] into the holes [C]. • Apply a non-permanent locking agent to the threads of the sidestand switch mounting bolt, and tighten it. T orque - Sidest and Switch Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)[...]

15-16 FRAME Frame Frame Inspection • Visua lly inspect the frame [A] for cracks, dents, bending, or warping. If there is any damage to the frame, replace it. WA R N I N G 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 16-1 16 Electrical System T able of Contents Parts Location.................................................................................................................. ....... 16-3 Exploded View ................................................................................................................... ..... 16-6 Spec[...]

16-2 ELECTRICAL SYSTEM Starter Motor Assembly .................................................................................................... 16-51 Brush Inspection ............................................................................................................... 1 6-53 Commutator Cleaning and Inspection...........................[...]

ELECTRICAL SYSTEM 16-3 Parts Location 1. Meter Unit 2. Ignition Switch 3. Front Brake Light Switch 4. Right Handlebar Switch 5. Left Handlebar Switch 6. Starter Lockout Switch 7. Horn 8. Ignition Coil 9. Spark Plug 10. W ater T emperature Sensor 1 1. Air Sw itching V al ve 12. Starter Motor 13. Regulator/Rectifier 14. Alternator 15. Crankshaft Sens[...]

16-4 ELECTRICAL SYSTEM Parts Location 16. Neutral Switch 17. Sidestand Switch 18. Starter Circuit Relay 19. Interlock Diode Unit 20. Starter Relay , Main Fuse 20 A 21. Fuse Box 22. Radiator Fan Relay 23. T urn Signal Relay 24. Battery 12 V 6 Ah 25. Radiator Fan Motor 26. Rear Brake Light Switch[...]

ELECTRICAL SYSTEM 16-5 Parts Location 27. Speed Sensor[...]

16-6 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 T iming Inspection Cap 2.3 0.23 20 in·lb 2 Alternator Rotor Bolt Cap 2.3 0.23 20 in·lb 3 Crankshaft Sensor Screws 2.4 0.24 21 in·lb 4 Starter Relay T erminal Screws 2.4 0.24 21 in·lb 5 Negative Brush Assy Mounting Screw 3.8 0.39 34 in·lb 6 Starter Motor Assy[...]

16-8 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 T ail/Brake Light Lens Screws 1.0 0.10 8.8 in·lb 2 T ail/Brake Light Mounting N uts 5.9 0.60 52 in·lb 3. MY and TH Models 4. IN Model 5. KLX250S9 Late Model ∼ SB/V9 Late Model ∼ VB (TH, MY) 6. KLX250SC/VC (TH, MY)[...]

16-10 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 16-1 1 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Left Switch Housing Screws 3.5 0.36 31 in·lb 2 Right Switch Housing Screws 3.5 0.36 31 in·lb 3 Sidestand Switch Mounting Bolt 8.8 0.90 78 in·lb L 4 Front Brake Light Switch Mounting Screw 1.2 0.12 11 i n · l b 5 Neutral Switch 14.7 1.5 130 in·lb G 6 Engine[...]

16-12 ELECTRICAL SYSTEM Specifications Fastener Standard Battery Ty p e Sealed battery Model Name FTX7L-BS Capacity 12 V 6 Ah V oltage 12.6 V or more Charging System Ty p e Three-phase AC Charging V oltage (Regulator/Rectifier Output V oltage) 14.2 ∼ 15.2 V Alternator output voltage (no load) 45 V or more @ 4 000 r/min (rpm) Stator Coil Resistanc[...]

ELECTRICAL SYSTEM 16-13 Special T ools and Sealant Rotor Puller , M16/M18/M20/M2 2 × 1.5 : 57001-1216 Jack: 57001-1238 Timing L ight: 57001-1241 Spark Plug W rench, Hex 16: 57001-1262 Hand T aster: 57001-1394 Peak V oltage Adapter: 57001-1415 Filler Cap Driver: 57001-1454 Needle Adapter Set : 57001-1457 Grip: 57001-1591 Rotor Holder: 57001-1723[...]

16-14 ELECTRICAL SYSTEM Special T ools and Sealant Liquid Gasket, TB121 1F: 92104-0004[...]

ELECTRICAL SYSTEM 16-15 Special T ools and Sealant This page intentionally left blank.[...]

16-16 ELECTRICAL SYSTEM Wiring Diagram (IN Model)[...]

ELECTRICAL SYSTEM 16-17 Wiring Diagram (IN Model)[...]

16-18 ELECTRICAL SYSTEM Wiring Diagram (MY and TH Mod els)[...]

ELECTRICAL SYSTEM 16-19 Wiring Diagram (MY and T H Models)[...]

16-20 ELECTRICAL SYSTEM Wiring Diagram (BR, EUR and SEA Models)[...]

ELECTRICAL SYSTEM 16-21 Wiring Diagram (BR, EUR and SEA Models)[...]

16-22 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below: Do not reverse the battery cable connections. This will burn out the diodes in the electrical parts. Always check battery condition before condemning other parts of an electrical s[...]

ELECTRICAL SYSTEM 16-23 Precautions Connectors [B][...]

16-24 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. 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 i[...]

ELECTRICAL SYSTEM 16-25 Battery Battery Removal NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the igniter . Never reverse the connections of the battery , as this could damage the igniter . • T urn the ignition switch OFF . • Remove the left side cover (see S[...]

16-26 ELECTRICAL SYSTEM Battery Batter y Activati on Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery . These names must be the same. Battery Model Name KLX250SC/VC: YTX7L-BS NOTICE Each battery comes with its own specific elec- trolyte container; using the wrong cont[...]

ELECTRICAL SYSTEM 16-27 Battery • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery . Hold the container level, push down to break the seals of all six cells. Y ou will see air bubbles rising into each cell as the ports fill. NOTE Do not tilt the electrolyte container. • Check the electro[...]

16-28 ELECTRICAL SYSTEM Battery Initial Charge • Newly activated sealed batteries require an initial charge. Standard Charge: 0.7 A × 5 10 hours If using a recommended battery charger , follow the charger ’s instructions for newly activated sealed battery . Kawasaki-recommended c hargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Y uasa M[...]

ELECTRICAL SYSTEM 16-29 Battery DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger , connect the battery to the charger before turning on the charger . This procedure prevents sp[...]

16-30 ELECTRICAL SYSTEM Battery T erm inal V oltage: 1 1 .5 less than 12.6 V Standard Charge 0.7 A × 5 10 h (see following chart) Quick Charge 3.0 A × 1.0 h NOTICE If possible, do not quick charge. If the quick charge is done unavoidably , do the standard charge later on. T erm inal V oltage: less th an 1 1.5 V Charging Method: 0 . 7A×2 0h NOTE [...]

ELECTRICAL SYSTEM 16-31 Charging System Alternat or Cover Remova l • Remove: Seat (see Seat Removal in the Frame chapter) Bolts [A] V ehicle-down Sensor Bracket [B] • Remove: Bands [A] • Disconnect the crankshaft sensor connector [B] and alter- nator connector [C]. • Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Dr[...]

16-32 ELECTRICAL SYSTEM Charging System Alternator Cover Installation • Install the dowel pins [A] into the crankcase. • Replace the gasket [B] with a new one. • Apply silicone sealant to the crankshaft sensor and stater coil leads grommet [A]. Sealant - Liquid Gasket, TB121 1F: 92104-0004 • T ighten: T orque - Alternator Cover Bolts: 9.8 N[...]

ELECTRICAL SYSTEM 16-33 Charging System • Remove: Idle Gear [A] Starter Motor Clutch Gear [B] Alternator Rotor Installation • Install the collar [A] so that the small outside diameter faces outward. • Install: Starter Motor Clutch Gear [A] Idle Gear [B] Spacer [C] • Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portio[...]

16-34 ELECTRICAL SYSTEM Charging System Stator Coil Removal • Remove: Alternator Cover (see Alternator Cover Removal) Stator Coil Bolts [A] Crankshaft Sensor Screws [B] Stator Coil Lead Holder [C] Grommet [D] • Remove the stator coil [E] and crankshaft sensor [F] as a set. Stator Coil Installation • Install the stator coil, and tighten the bo[...]

ELECTRICAL SYSTEM 16-35 Charging System Alternator Output V oltage Connections Te s t e r Range T ester (+) Lead Connection Te s t e r ( – ) L e a d Connection Standard @4 000 rpm AC 250 V One Y ellow Lead Another Y ellow Lead 45 V or more Repeat testing other yellow leads. Hand T ester [A] If the output voltage shows the value in the table, the [...]

16-36 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal • Remove the regulator/rectifier connector [A]. • Remove the bolts [B], and then remove the regu lator/rec- tifier [C]. Regulator/Rectifier Installation • Install: Regulator/Rectifier • T ighten: T orque - Regulat or/Rectifie r Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·l[...]

ELECTRICAL SYSTEM 16-37 Charging System Regulator/Rectifier Inspection • Remove the regulator/rectifier (see regulator/rectifier Re- moval). Rectifier Circuit Check • Check conductivity of the following pair of terminals. Rectifier C ircuit Insp ection W-Y1, W-Y2 , W-Y3 T ester connection BK /Y-Y1, BK/Y-Y2, BK/Y-Y3, The resistance should be low[...]

16-38 ELECTRICAL SYSTEM Charging System • Do the 3rd step regulator circuit test. Connect the test light and the 12 V battery in the same manner as specified in the “Regulator Circuit T est-1st Step”. Momentarily apply 24 V to the v oltage BR terminal by adding a 12 V battery . Check the Y1, Y2 and Y3 terminals respectively . NOTICE Do not ap[...]

ELECTRICAL SYSTEM 16-39 Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Alternator 4. Regulator/Rectifier 5. Starter Relay 6. Main Fuse 20 A 7. Battery 12 V 6 Ah 8. Frame Ground[...]

16-40 ELECTRICAL SYSTEM Ignition System Ignition Timing Inspection • Remove the timing inspection cap [A]. Special T ool - Filler Cap Driver: 57001-1454 • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer . Special T ool - Timing Light: 57001-1241 • Start the engine and aim the timing l ight at[...]

ELECTRICAL SYSTEM 16-41 Ignition System Crankshaft Sensor Inspection • Remove the left side cover (see Left Side Cover Removal in the Frame chapter). • Disconnect the crankshaft sensor lead connector . • Set the hand tester [A] to the ×100 range and connect it to the crankshaft sensor lead connector [B]. Special T ool - Hand T ester: 57001-1[...]

16-42 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • Remove: Fuel T ank (see Fuel T ank Removal in the Fuel System (DFI) chapter) • Pull off the spark plug cap [A] from the spark plug. • Remove: Ignition Coil Bolts [A] Ignition Coil [B] • Disconnect the ignition coil primary connector [A]. Ignition Coil Installation • Connect t[...]

ELECTRICAL SYSTEM 16-43 Ignition System Ignition Coil Inspection • Remove the ignition coil (see Ignition Coil Removal). • Measure the arcing distance with a suitable commercially available coil tester [A] to check the condition of the igni- tion coil [B]. • Connect the ignition coil (with the spark plug cap left at- tached) to the tester in [...]

16-44 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Inspection NOTE Be sure the battery is fully charged. • Remove: Left Radiator Shroud (se e Radiator Shroud Removal in the Frame chapter) • Pull off the spark plug cap from the spark plug (see Igni- tion Coil Removal). Do not remove the spark plug. • Measure the primary[...]

ELECTRICAL SYSTEM 16-45 Ignition System Spark Plug Installation • Refer to the Spark Plug Replacement in the Period ic Maintenance chapter . Spark Plug Cleaning and Inspection • Remove the spark plug (see S park Plug Replacement in the Periodic Maintenance chapter). • Clean the spark plug, preferably in a sandblasting device, and then clean o[...]

16-46 ELECTRICAL SYSTEM Ignition System 3rd Check • Inspect the engine for its secure stop after the following operations are completed. • Run the engine to the following conditions. Condition T ransmission Ge ar 1st Position Clutch Lever Pulled in Sidestand Up • Set the sidestand on the ground, then the engine will stop. If whichever may not[...]

ELECTRICAL SYSTEM 16-47 Ignition System Ignition System T roubleshooting[...]

16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 2. Starter Lockout Switch 3. Ignition Coil 4. Spark Plug 5. Crankshaft Sensor 6. Neutral Switch 7. ECU 8. Starter Relay 9. Main Fuse 20 A 10. Battery 12 V 6 Ah 1 1. Frame Ground 12. Fuse Box 13. Ignition Fuse 10 A 14. ECU Fuse 15 A 15. Interlock Diode Unit 16. Sidest[...]

ELECTRICAL SYSTEM 16-49 Starter Motor Starter Motor Removal NOTICE Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Remove: Left Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) T orque Limiter (see T orque Limiter Removal in the Crankshaft/T ransmission chapter) • Remove: Bolt[...]

16-50 ELECTRICAL SYSTEM Starter Motor • Replace the O-ring [A] with a new one. • Apply grease to the O-ring. • T ighten: T orque - Starter Motor Mounting Bolts: 9.8 N·m (1 .0 kg f·m, 87 in·lb) • Position the starter motor cable [A] as shown. 90° [B] Rear [C] • T ighten: T o rque - Starter M otor C able Nut: 9.8 N·m (1 .0 kgf· m, 87 [...]

ELECTRICAL SYSTEM 16-51 Starter Motor • Remove: O-ring [A] • Pull out the brushes from the brush holder [A]. • Remove: Brush Springs [B] Starter Motor T erminal [C] Positive Brush Assy [D] Negative Brush Assy Mounting Screw [E] Negative Brush Assy [F] Brush Holder Starter Motor Assembly • Align the hole [A] of the brush holder [B] to the bo[...]

16-52 ELECTRICAL SYSTEM Starter Motor • Replace the O-ring [A] with a new one. • Install the following parts to the starter motor terminal [B]. O-ring Collar [C] W asher [D] Starter Motor T erminal Locknut [E] Install the collar so that stepped side faces outward. • T ighten: T orque - Starte r Motor T erminal Locknut: 1 1 N·m (1.1 kgf·m, 9[...]

ELECTRICAL SYSTEM 16-53 Starter Motor • Align the marks [A] to assembly the yoke and the end covers [B]. • T ighten: T o rque - Starter Moto r Assy Bolts [A ]: 5.0 N·m (0 .51 kgf·m , 44 in·lb) Brush Inspection • Measure the length of each brush [A]. If any is worn down to the service limit, replace the brush assy . Starter Motor Brush Leng[...]

16-54 ELECTRICAL SYSTEM Starter Motor Armature Inspection • Using the × 1 hand tester range, measure the resis- tance between any two commutator segments [A]. Special T ool - Hand T ester: 57001-1394 If there is a high resistance or no reading ( ) between any two segments, a winding is open and the starter motor must be replaced. • Using the h[...]

ELECTRICAL SYSTEM 16-55 Starter Motor • Push the rear fender front downward, remove the starter relay [A] from the rear fender front. Starter Relay Inspection • Remove: Starter Relay (see Starter Relay Removal) • Connect the hand tester [A] a nd 12 V battery [B] to the starter relay [C] as shown. Special T ool - Hand T ester: 57001-1394 If th[...]

16-56 ELECTRICAL SYSTEM Starter Motor Electrical Starter Circuit 1. Ignition Switch 2. Starter Lockout Switch 3. Neutral Switch 4. Starter Relay 5. Main Fuse 20 A 6. Battery 12 V 6 Ah 7. Frame Ground 8. Fuse Box 9. Ignition Fuse 10 A 10. Starter Circuit Relay 1 1. Diode 12. Interlock Diode Unit 13. Sidestand Switch 14. Starter Button 15. Engine Sto[...]

ELECTRICAL SYSTEM 16-57 Lighting System Headlight Body Removal • Remove: Front Fender (see Front Fender Removal in the Frame chapter) Bolts [A] Headlight/Meter Cover [B] • Remove the headlight body mounting bolts [A]. • Pull the headlight body [B] forward. IN and EUR Models • Disconnect the headlight connector [A] and city light con- nector[...]

16-58 ELECTRICAL SYSTEM Lighting System Headlight Bulb Replacement SEA, BR, IN and EUR Models • Remove the headlight body (see Headlight Body Re- moval). • Remove the headlight bulb dust cover [A] from the head- light body . • Disconnect the connector [A]. • Push the hook [B] to unlock the headlight bulb. • R e m o v et h eb l u b[ C ] . [...]

ELECTRICAL SYSTEM 16-59 Lighting System MY and TH Models • Remove the headlight body (see Headlight Body Re- moval). • Remove the headlight bulb dust covers [A] from the head- light body . • Push and turn the lead plates [A] counterclockwise, and remove it. • Remove the bulbs [A]. NOTICE When handling the quartz-halogen bulb, never touch th[...]

16-60 ELECTRICAL SYSTEM Lighting System • Fit the dust cover with the TOP mark [A] upward. • Check the dust cover onto the headlight body as shown. Correct [A] Incorrect [B] City Light Bulb Replacemen t (SEA, BR, IN and EUR Models) • Remove the headlight body (see Headlight Body Re- moval). • Pull out the socket [A] together with the bulb. [...]

ELECTRICAL SYSTEM 16-61 Lighting System • Remove: Nuts [A] T ail/Brake Light Unit T ail/Brake Light Bu lb Replacement • Remove: Rear Fender Rear (see Rear Fender Rear Removal in the Frame chapter) Screws [A] • Clear the stoppers [A] from the tail/brake light body with a screwdriver [B] to remove the lens [C]. • Push and turn the bulb [A] co[...]

16-62 ELECTRICAL SYSTEM Lighting System • Install the taillight lens so that the stopper [A] fit the slits [B]. • T ighten: T orque - T ail/Brake Light Lens Screws: 1.0 N·m (0.10 kg f·m, 8.8 in·lb) Headlight/T ail Light Circuit (IN Model) 1. Ignition Switch 2. Lighting Switch 3. Headlight 12 V 60/55 W 4. City Light 12 V 5 W 5. Meter Unit 6. [...]

ELECTRICAL SYSTEM 16-63 Lighting System Headlight/T ail Light Circu it (BR, EUR and SEA Models) 1. Ignition Switch 2. Headlight 12 V 60/55 W 3. City Light 12 V 5 W 4. Meter Unit 5. High Beam Indicator Light (LED) 6. Dimmer Switch 7. Starter Relay 8. Main Fuse 20 A 9. Battery 12 V 6 Ah 10. Frame Ground 1 1. T ail/Brake Light 12 V 21/5 W 12. T o Fron[...]

16-64 ELECTRICAL SYSTEM Lighting System Headlight/T ail Light Circuit (MY and TH Mod els) 1. Ignition Switch 2. Headlight 12 V 30/30 W × 2 3. Meter Unit 4. High Beam Indicator Light (LED) 5. Dimmer S witch 6. Starter Relay 7. Main Fuse 20 A 8. Battery 12 V 6 Ah 9. Frame Ground 10. T ail/Brake Light 12 V 21/5 W 1 1. T o Front/Rear Brake Light Switc[...]

ELECTRICAL SYSTEM 16-65 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. • Install the turn signal light lens. • T ighten the turn signal light lens screw . Be careful not to overtighten it. Turn Signal Relay Inspection NOTICE Ne[...]

16-66 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit 1. Ignition Switch 2. T urn Signal Relay 3. Front Right T urn Signal Light 12 V 10 W 4. Meter Uni t 5. T urn Signal Indicator Light (LED) 6. Front Left T urn Signal Light 12 V 10 W 7. T urn Signal Switch 8. Starter Relay 9. Main Fuse 20 A 10. Battery 12 V 6 Ah 1 1. Frame Ground 12. [...]

ELECTRICAL SYSTEM 16-67 Air Switching V alve Air Switching V alve Operation T est • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter . Air Switching V alve Unit T est • Remove the air switching valve (see Air Switching V alve Removal in the Engine T op End chapter). • Set the hand tester [A] to the × rang[...]

16-68 ELECTRICAL SYSTEM Air Switching V alve Air Switching V alve Circuit 1. Ignition Switch 2. ECU 3. Starter Relay 4. Main Fuse 20 A 5. Battery 12 V 6 Ah 6. Fuse Box 7. Ignition Fuse 10 A 8. Air Switching V alve[...]

ELECTRICAL SYSTEM 16-69 Radiator Fan System Radiator Fan Relay Inspection • Remove: Seat (see Seat Removal in the Frame chapter) Fan Relay [A] • Connect the hand tester [A] and a 12 V battery [B] to the starter circuit relay [C] as shown. Special T ool - Hand T ester: 57001-1394 If the relay does not work as specified, the relay is defec- tive.[...]

16-70 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. Ignition Switch 2. Radiator Fan 3. Fan Relay 4. ECU 5. Starter Relay 6. Main Fuse 20 A 7. Battery 12 V 6 Ah 8. Frame Ground 9. Fuse Box 10. Radiator Fan Fuse 10 A 1 1. W ater-proof Joint 12. W ater T emperature Sensor[...]

ELECTRICAL SYSTEM 16-71 Meter , Gauge Meter Unit Removal • Remove: Headlight/Meter Cover (see Headlight Body Removal) Screws [A] and W asher Meter Unit [B] • Disconnect the meter connector [C]. NOTICE Do not drop the meter unit. Place the meter unit so that face is up. If a meter unit is left upside down or sideways for a long time or dropped, [...]

16-72 ELECTRICAL SYSTEM Meter , Gauge Meter Unit Inspection • Remove the meter unit [A] (see Meter Unit Removal). [1] T achometer Signal [2] Speed Sensor Signal [3] Unused [4] Unused [5] Speed Sensor Power Supply [6] Ground (–) [7] Ignition [8] Battery (+) [9] Neutral Indicator Light (LED) (–) [10] High Beam Indicator Light (LED) (+) [1 1] Ri[...]

ELECTRICAL SYSTEM 16-73 Meter , Gauge When the terminals are connected, all the LCD segments [A] and all indicator lights (LED) [B] appear for three sec- onds. When the terminals are connected, tachometer momen- tarily goes from the minimum to the maximum, then goes back from the maximum to the minimum reading. If the LCD segments will not appear ,[...]

16-74 ELECTRICAL SYSTEM Meter , Gauge MODE AND RESET BUTTON Operation Check • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Check that the display [A] change to the ODO, TRIP A and TRIP B displays each time the MODE button [B] is pressed. If the displ[...]

ELECTRICAL SYSTEM 16-75 Meter , Gauge • In the MINUTE setting mode, press the RESET button to return to the HOUR/MINUTE setting mode. • Press the MODE button to complete the time setting process. The clock starts counting the seconds a soon as the MODE button is pressed. • Indicate the ODO mode. • Check that the display [A] change to the mi[...]

16-76 ELECTRICAL SYSTEM Meter , Gauge Odometer Check • Check the odometer with the speedometer check in the same way . If value indicated i n the odometer is not added, replace the meter assembly . NOTE The data is maintained even if the battery is discon- nected. When the figures come to 999999, they are stopped and locked. T rip Meter Check •[...]

ELECTRICAL SYSTEM 16-77 Meter , Gauge Lights (LED) Inspection • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid C rystal Display (LCD) Seg- ments check”. FI Indicator Light (LED) [A] Illumination Light (LED) [B] Fuel Level W arning Indicator Light (LED) [C] W ater T emperature W arning Indicator Light ([...]

16-78 ELECTRICAL SYSTEM Meter , Gauge Right and Left T urn Signal Indicator Light (LED) Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments check”. • Using the insulated auxiliary leads, 12 V battery to the meter unit connector as follows. Connect the battery positive (+) te[...]

ELECTRICAL SYSTEM 16-79 Meter , Gauge • Disconnect the terminal [16]. When the terminals are disconnected, the fuel level warn- ing indicator light (LED) [A] blinks and FUEL segment [B] blinks by display . If the fuel level warning indicator light (LED) does not blink or FUEL segment do not display , replace the meter unit. • Connect the batter[...]

16-80 ELECTRICAL SYSTEM Meter , Gauge Meter Unit Circuit 1. Ignition Switch 2. Meter Unit 3. T urn Signal Indicator Light (LED) 4. High Beam Indicator Light (LED) 5. Neutral Indicator Light (LED) 6. W ater T emperature Warning Light (LED) 7. FI Indicator Light (LED) 8. Fuel Level Warning Light (LED) 9. Odometer/T rip Meter 10. Clock 1 1. T achomete[...]

ELECTRICAL SYSTEM 16-81 Switches and Sensors Water T emperature Sensor Inspection • Remove the water temperature sensor (see W ater T em- perature Sensor Removal/Installation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged. • Suspen[...]

16-82 ELECTRICAL SYSTEM Switches and Sensors • Remove the speed sensor lead from the c lamps [A] at the fork protecter . • Remove: Front Wheel (see Front Wheel Removal in the Wheels/T ires chapter) Speed Sensor [B] Speed Sensor Insta llation • Apply grease to the speed sensor seal lip [A]. • Install the speed sensor so that grooves [B] of t[...]

ELECTRICAL SYSTEM 16-83 Switches and Sensors Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely . • Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Fuel Pump Lead Connector • Connect the test light [A] (12 V 3.4 W bulb in a socket with leads) and the 12 V battery [B] to the[...]

16-84 ELECTRICAL SYSTEM Switches and Sensors • Remove the oxygen sensor [A]. Oxygen Sensor I nstallation NOTICE Never drop the Oxygen Sensor [A] especially on a hard surface. Su ch a shock to the unit can damage it. Do not touch the sensing part [B] to prevent oil con- tact. Oil contamination from hands can reduce sen- sor performance. • T ight[...]

ELECTRICAL SYSTEM 16-85 Switches and Sensors • Remove: Subthrottle Sensor Connector [A] Bands [B] Sidestand Switch Connector [C] • Remove: Bolt [A] Sidestand Switch Cover [B] Sidestand Switch [C] Sidestand Switch Installa tion • Install the sidestand switch (see Sidestand Installation in the Frame chapter). • Apply a non-parmanent locking a[...]

16-86 ELECTRICAL SYSTEM Switches and Sensors Switch Inspection • Using a hand tester , check to see that only the connec- tions shown in the table have continuity . Special T ool - Hand T ester: 57001-1394 For the switch housings and the ignition switch, refer to the tables in the Wiring Diagram. If the switch has an open or short, repair it or r[...]

ELECTRICAL SYSTEM 16-87 Fuse 20 A Main Fuse Remo val • Remove the seat (see Seat Removal in the Frame chap- ter). • Disconnect the starter relay connector [A]. • Pull out the main fuse [A] from the starter relay with needle nose pliers. Fuse Box Fuse Removal • Remove the seat (see Seat Removal in the Frame chap- ter). • Unlock the hooks [[...]

16-88 ELECTRICAL SYSTEM Fuse Fuse Inspection • Remove the fuse (see 20 A Main Fuse/Fuse Box Fuse Removal). • Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the af fected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related [...]

APPENDIX 17-1 17 Appendix T able of Contents Cable, Wire, and Hose Routing .............................................................................................. 17-2 T roubleshooting Guide ........................................................................................................... 17-30[...]

17-2 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Air Switching V alve 2. Air Switching V alve Hose (T o Air Suction V alve) 3. Air Switching V alve Hose (T o Fitting) 4. Air Switching V alve Hose (T o Air Cleaner Housing) 5. Align the white mark of the air switching valve hose and the mark of the air suction valve cover . 6. Fuel Hose (T o Fuel Pump)[...]

17-4 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Air Switching V alve 2. Install the air switching valve hose to the air switching valve so that the white ma rk faces upper side. 3. Air Switching V alve Hose (T o Fitting) 4. Air Switching V alve Hose (T o Air Suction V alve) 5. Install the air switching valve hose to the fitting so that the white mar[...]

17-6 APPENDIX Cable, Wire, and Hose Routing 1. T o Alternator Cover 2. Alternator/Crankshaft Sensor Lead 3. Fuel T ank Breather Hose 4. T o Feul T ank 5. Fuel T ank Drain Hose 6. T o Regulator/Rectifier 7. Run the regulator/rectifier lead to the bracket guide. 8. Engine Ground Cable 9. T o Neutral Switch 10. Neutral Switch Lead 1 1. 45° 12. Clamp [...]

APPENDIX 17-7 Cable, Wire, and Hose Routing 1. T o Main Harness 2. Clamps (Set th e bolt head of the clamp as shown in figure.) 3. Face the white mark upper side. 4. About 60° 5. Face the white mark right side.[...]

17-8 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Reserve T ank Overflow Hose 2. Clamp (Run the reserve tank overflow hose to the clamp on the frame.) 3. Reserve T ank Hose 4. T o Radiator 5. Run the reserve tank overflow hose between the rear fender rear and frame. 6. Reserve T ank[...]

17-10 APPENDIX Cable, Wire, and Hose Routing 1. Reserve T ank 2. Reserve T ank Overflow Hose 3. Clamp 4. Install the overflow h ose so that the hose end is along the inside of the rear flap. 5. Reserve T ank Hose 6. Clamp (Bend the clamp to hold the reserve tank hose as shown in the figure.) 7. Frame Pipe 8. V iewed from A-A[...]

APPENDIX 17-1 1 Cable, Wire, and Hose Routing 1. Throttle Cable (Decelector) 2. Throttle Cable (Accelerator) 3. Main Harness 4. Reserve T ank Hose 5. Run the throttle cables and reserve tank hose inside of the fuel tank. 6. Run the throttle cables under the radiator hose. 7. Clutch Cable 8. About 90° 9. About 90° 10. Clamp (Ru n the main harness [...]

17-12 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Air Switching V alve Hose 2. Fuel T ank Breather Hose 3. Fuel T ank Drain Hose 4. Run the fuel tank breather and drain hose inside of the air switching valve hose. 5. W ater T emperature Sensor 6. Main Throttle Sensor 7. Run the fuel tan k breather hose and drain hose outside of the water temperature [...]

17-14 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Alig n the white mark of the main harness and the frame hook. 2. Run the main harness under the frame cross pipe. Align the white mark to the frame c ross pipe. 3. Fuel Injector 4. Inlet Air T emperature Sensor 5. Fan Relay 6. T urn Signal Relay 7. Starter Circuit Relay 8. Interlock Diode Unit 9. Clam[...]

17-16 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Guide (Run the left and right switch housing leads and reserve tank hose to the guide.) 2. Reserve T ank Hose 3. Right Switch Housing Connector 4. Left Switch Housing Connector 5. Frame Ground T erminal 6. Viewed from A 7. Inlet Air Pressure Sensor 8. Main Throttle Sensor 9. Subthrottle V alve Actuato[...]

17-18 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Band (Clamp the main harness.) 2. Fuel Pump Connector 3. Align t he white mark on the main harness to the frame bracket. 4. Position the r ear barake light switch connector at the inside of the rear barake reservoir tank. 5. Fuel Pump Relay 6. Run the rear brake lig ht switch lead to the frame guide. [...]

17-20 APPENDIX Cable, Wire, and Hose Routing Other than TH and KLX250S9 Early Model (TH)/V9 Early M odel (TH)[...]

APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Clamp (Clamp the switch housing lead.) 2. Run the brake hose over the throttle cables. 3. Throttle Cables 4. Run the clutch cable forward of the front brake hose, and run it backward of the left and right switch housing leads and other lead wire. The clutch cable crosses the frame head pipe front from[...]

17-22 APPENDIX Cable, Wire, and Hose Routing KLX250S9 Late Model S B / V 9L a t eM o d e l VB (TH, MY)[...]

APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Clamp (Clamp the switch housing lead.) 2. Run the brake hose over the throttle cables. 3. Throttle Cables 4. Run the clutch cable forward of the front brake hose, and run it backward of the left and right switch housing leads and other lead wire. The clutch cable crosses the frame head pipe front from[...]

17-24 APPENDIX Cable, Wire, and Hose Routing KLX250SC/VC (TH, MY)[...]

APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Clamp (Clamp the switch housing lead.) 2. Run the brake hose over the throttle cables. 3. Throttle Cables 4. Run the clutch cable forward of the front brake hose, and run it backward of the left and right switch housing leads and other lead wire. The clutch cable crosses the frame head pipe front from[...]

17-26 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Front Brake Caliper 2. Front Brake Hose 3. Clamp 4. Run the front brake hose inside of the front fork. 5. Run the front brake hose along the guide on the fork protector . 6. Align the white mark on the speed sensor lead with the clamp. 7. Clamp 8. Clamp 9. Speed Sensor 10. Install the bracket so that [...]

17-28 APPENDIX Cable, Wire, and Hose Routing SEA and TH Models[...]

APPENDIX 17-29 Cable, Wire, and Hose Routing 1. White Paints 2. Green P aints 3. Blue Paints 4. Fitting 5. T o Throttle Body Assy 6. T o Air Cleaner Housing 7. Separator 8. Red P aints 9. T o Ignition Coil 10. White Line Hose 1 1. Canister[...]

17-30 APPENDIX T roubleshooting Guide NOTE Refer to the Fuel System chapter for most of DFI trouble shooting guide. 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. Engine Doesn’t Start, Starting Difficul[...]

APPENDIX 17-31 T roubleshooting Guide Cylinder , piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head warped Cylinder head gasket damaged V alve spring broken or weak V alve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Backfiring when deceleratio[...]

17-32 APPENDIX T roubleshooting Guide Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect: Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble ECU trouble Radiator fan relay trouble Fan motor broken Fan blade damaged W ater pump not turning W ater pump impeller damaged Over Cooling: Cooling sy[...]

APPENDIX 17-33 T roubleshooting Guide Clutch housing gear worn Wrong installation of outside friction plate T ransmission noise: Bearings worn T ransmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise: Drive chain adjusted improperly Drive chain worn Rear and/or engine sprocket worn Rear wheel misa[...]

MODEL APPLICA TION Ye a r Model Beginning Frame No. 2009 KLX250S9 JKALX250S DA00001 JKALX250SSDA00548 LX250S-A00540 2009 KLX250V9 LX250V-A00832 2010 KLX250SA JKALXMS1 ADA06540 JKALX250SSDA06540 JKALX250S DA06535 2010 KLX250V A JKALXMV1 ADA03155 201 1 KLX250SB JKALXMS1 BDA07967 JKALX250SSDA07967 201 1 KLX250VB JKALX250VVDA04685 2012 KLX250SC JK ALXM[...]