2012KawasakiKLX250ServiceManualnew

KLX250D-TRACKERXMotorcycleServiceManualThisquickreferenceguidewillassistyouinlocatingadesiredtopicorpro-cedure.•Bendthepagesbacktomatchtheblacktabofthedesiredchapternum-berwiththeblacktabontheedgeateachtableofcontentspage.•Refertothesectionaltableofcontentsfortheexactpagestolocatethespe-cifictopicrequired.QuickReferenceGuideGeneralInformation1jPeriodicMaintenance2jFuelSystem(DFI)3jCoolingSystem4jEngineTopEnd5jClutch6jEngineLubricationSystem7jEngineRemoval/Installation8jCrankshaft/Transmission9jWheels/Tires10jFinalDrive11jBrakes12jSuspension13jSteering14jFrame15jElectricalSystem16jAppendix17jKLX250D-TRACKERXMotorcycleServiceManualAllrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise,withoutthepriorwrittenpermissionofQualityAssuranceDivision/Motorcycle&EngineCompany/KawasakiHeavyIndustries,Ltd.,Japan.Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossiblecarehasbeentakentomakeitascompleteandaccurateaspossible.Therightisreservedtomakechangesatanytimewithoutpriornoticeandwithoutincurringanobligationtomakesuchchangestoproductsmanufacturedpreviously.SeeyourMotorcycledealerforthelatestinformationonproductimprovementsincorporatedafterthispublication.Allinformationcontainedinthispublicationisbasedonthelatestproductinformationavailableatthetimeofpublication.Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmaynotdepictactualmodelcomponentparts.©2008KawasakiHeavyIndustries,Ltd.6thEdition(0):Jun.3,2011LISTOFABBREVIATIONSAampere(s)lbpound(s)ABDCafterbottomdeadcentermmeter(s)ACalternatingcurrentminminute(s)ATDCaftertopdeadcenterNnewton(s)BBDCbeforebottomdeadcenterPapascal(s)BDCbottomdeadcenterPShorsepowerBTDCbeforetopdeadcenterpsipound(s)persquareinch°Cdegree(s)CelsiusrrevolutionDCdirectcurrentrpmrevolution(s)perminuteFfarad(s)TDCtopdeadcenter°Fdegree(s)FahrenheitTIRtotalindicatorreadingftfoot,feetVvolt(s)ggram(s)Wwatt(s)hhour(s)✂ohm(s)Lliter(s)COUNTRYANDAREACODESBRBrazilMYMalaysiaEUREuropeSEASoutheastAsiaINIndonesiaTHThailandForewordThismanualisdesignedprimarilyforusebytrainedmechanicsinaproperlyequippedshop.However,itcontainsenoughdetailandbasicin-formationtomakeitusefultotheownerwhode-sirestoperformhisownbasicmaintenanceandrepairwork.Abasicknowledgeofmechanics,theproperuseoftools,andworkshopproce-duresmustbeunderstoodinordertocarryoutmaintenanceandrepairsatisfactorily.When-evertheownerhasinsufficientexperienceordoubtshisabilitytodothework,alladjust-ments,maintenance,andrepairshouldbecar-riedoutonlybyqualifiedmechanics.Inordertoperformtheworkefficientlyandtoavoidcostlymistakes,readthetext,thor-oughlyfamiliarizeyourselfwiththeproceduresbeforestartingwork,andthendotheworkcare-fullyinacleanarea.Wheneverspecialtoolsorequipmentarespecified,donotusemakeshifttoolsorequipment.Precisionmeasurementscanonlybemadeiftheproperinstrumentsareused,andtheuseofsubstitutetoolsmayad-verselyaffectsafeoperation.Forthedurationofthewarrantyperiod,werecommendthatallrepairsandscheduledmaintenancebeperformedinaccordancewiththisservicemanual.Anyownermaintenanceorrepairprocedurenotperformedinaccordancewiththismanualmayvoidthewarranty.Togetthelongestlifeoutofyourvehicle:•FollowthePeriodicMaintenanceChartintheServiceManual.•Bealertforproblemsandnon-scheduledmaintenance.•UsepropertoolsandgenuineKawasakiMo-torcycleparts.Specialtools,gauges,andtestersthatarenecessarywhenservicingKawasakimotorcyclesareintroducedbytheServiceManual.GenuinepartsprovidedassparepartsarelistedinthePartsCatalog.•Followtheproceduresinthismanualcare-fully.Don’ttakeshortcuts.•Remembertokeepcompleterecordsofmain-tenanceandrepairwithdatesandanynewpartsinstalled.HowtoUseThisManualInthismanual,theproductisdividedintoitsmajorsystemsandthesesystemsmakeupthemanual’schapters.TheQuickReferenceGuideshowsyoualloftheproduct’ssystemandassistsinlocatingtheirchapters.EachchapterinturnhasitsowncomprehensiveTableofContents.Forexample,ifyouwantignitioncoilinforma-tion,usetheQuickReferenceGuidetolocatetheElectricalSystemchapter.Then,usetheTableofContentsonthefirstpageofthechap-tertofindtheignitioncoilsection.Wheneveryouseesymbols,heedtheirin-structions!Alwaysfollowsafeoperatingandmaintenancepractices.DANGERDANGERindicatesahazardoussitua-tionwhich,ifnotavoided,willresultindeathorseriousinjury.WARNINGWARNINGindicatesahazardoussitua-tionwhich,ifnotavoided,couldresultindeathorseriousinjury.NOTICENOTICEisusedtoaddresspracticesnotrelatedtopersonalinjury.Thismanualcontainsfourmoresymbolswhichwillhelpyoudistinguishdifferenttypesofinformation.NOTE✁Thisnotesymbolindicatespointsofpar-ticularinterestformoreefficientandcon-venientoperation.•Indicatesaproceduralsteporworktobedone.Indicatesaproceduralsub-steporhowtodotheworkoftheproceduralstepitfollows.ItalsoprecedesthetextofaNOTE.Indicatesaconditionalsteporwhatactiontotakebasedontheresultsofthetestorinspec-tionintheproceduralsteporsub-stepitfol-lows.Inmostchaptersanexplodedviewillust