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Kawasaki KR250 [3/183] General information

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Quick reference guide 2
General information 3
Table of contents 3
Genera 5
8 general information 10
Air cleaner e i em ent rep lace 5 cleanings 10
Air cleaner element clean 10
Battery electrolyte level check f month 10
Brake fluid change 2 years 10
Brake fluid level check t month 10
Brake light switch check f 10
Brake pad wear check f 10
Caliper piston seal and dust seal replace 2 years 10
Check f 10
Clutch adjust 10
Coolant change 2 years 10
Cylinder head bolts check f 10
Drive chain lubricate every 300 km 10
Drive chain slack check f every 800 km_______________________ 10
Drive chain wear check f 10
For higher odometer readings repeat at the frequency interval established here t replace add adjust or torque if necessary 10
Frequency 10
Front fork oil change 10
Fuel hose replace 4 years 10
Fuel system clean 10
General lubrication perform 10
Good running condition 10
Idle speed check f 10
Master cylinder cup and dust seal replace brake hose replace 10
Nuts bolts fasteners check t 10
Oh pump and carburetor synchronization 10
Operation 10
Periodic maintenance chart 10
Radiator hoses connections check f year 10
Spark plug clean and gap t 10
Steering play check 10
Steering stem bearing lubricate 2 years 10
Swing arm pivot lubricate 10
The initial maintenance is vitally important and must not be neglected 10
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in 10
Throttle grip play check t 10
Tire wear check 10
Transmission oil change year 10
Whichever con hrsth _ odometer reading 10
Years 4 years 10
1 11 0 13
Coolant temperature sensor 15 1 11 ss 13
Electrical system 13
Fastener torque 13
General information 1 11 13
Magneto rotor bolt 69 7 13
Neutral switch 13
Nm kg m ft lb 13
Remarks 13
Side stand switch mounting screws 13
Spark plugs 27 2 13
12 general information 14
Suggested wiring cable ar hase routing 14
General information 1 13 15
General information 16
V iflfeiv v j j 16
______ 16
General information 1 15 17
16 general information 18
General information 1 17 19
18 general information 20
General information 1 19 21
Fuel system 22
Table of contents 22
Fuel system 25
Specifications special tools 25
Fuel system 2 5 26
Grip play inspection 26
Throttle grip and cables 26
Throttle grip play adjustment 26
Warning 1 26
3 fuel system 27
Choke cable adjustment 27
Choke cables 27
Throttle cable inspection 27
Throttle cable lubrication 27
Throttle cable removal note 27
Warmins 27
Carburetors 28
Choke cable inspection 28
Choke cable lubrication 28
Choke cable removal 28
Fuel system 2 7 28
I die speed adjustment 28
Warning i 28
8 fuel system 29
Fuel level inspection 29
Float removal 30
Fuel level adjustment 30
Fuel system 2 9 30
Fuel system cleanliness inspection 30
Warn img 30
Carburetor cleaning 31
Carburetor installation notes 31
Carburetor removal 31
Id fuel system 31
Warnin 31
Warning i 31
Carburetor inspection 32
Fuel system 2 11 32
Warming 32
12 fuel system 33
Air cleaner 33
Air cleaner element removal installation 33
Caution 33
Element inspection and cleaning 33
Warning 33
A ir cleaner housing removal 34
Air cleaner housing installation note 34
Fuel system 2 13 34
Fuel tank 34
Fuel tank removal 34
Warning 34
Warning j 34
14 fuel system 35
Fuel tank and tap cleaning 35
Fuel tap assembly note 35
Fuel tap inspection 35
Fuel tap installation note 35
Wardin 35
Fuel system 2 15 36
Fuel tank and cap inspection 36
Reed valve 36
Reed valve inspection 36
Reed valve removal 36
16 fuel system 37
Idle speed adjustment from page 2 8 37
Warming 37
Cooling system 38
Table of contents 38
2 cooling system 39
Exploded view 39
1 cooling system 41
Cautio 41
Coolant 41
Coolant deterioration 41
Coolant draining 41
Coolant level inspection 41
Warniwc 41
Caution 42
Coolant filling 42
Cooling system 3 5 42
Caution 43
Cooling system 43
Cooling system flushing 43
Cooling system pressure testing 43
Visual leak inspection 43
Caution 44
Cooling system 3 7 44
Disassembly and assembly precautions 44
Pump cover removal 44
Pump impeller removal installation notes 44
Water pump disassembly 44
Water pump mechanical seal 44
8 cooling system 45
Pump assembly notes 45
Cooling system 3 9 46
Mechanical seal inspection 46
Radiator 46
Radiator inspection 46
Radiator removal 46
10 cooling system 47
Radiator cap inspection 47
Thermostat 47
Thermostat inspection 47
Thermostat installation note 47
Cautíorh 48
Cooling system 3 11 48
Installation notes 48
Removal caution 48
Water temperature sensor 48
Engine top end 49
Table of contents 49
Engine top end 4 3 51
Caution 53
Compression measurement 53
Cylinder head 53
Cylinder head removal 53
Engine top end 4 53
6 engine top end 54
Cylinder head installation notes 54
Cylinder head warp inspection 54
Exhaust valve kips 54
Exhaust valve operating unit removal 54
Cautio 55
Engine top end 4 7 55
Exhaust valve installation notes 55
Exhaust valve operating unit installation 55
8 engine top end 56
Cylinder assembly note 56
Cylinder installation notes 56
Cylinder piston 56
Cylinder removal 56
Cylinder wear inspection 56
Caution 57
Engine top end 4 9 57
Piston installation notes 57
Piston removal notes 57
10 engine top end 58
Piston cylinder clearance 58
Piston diameter measurement 58
Piston ring piston ring groove inspection 58
Connecting rod wear inspection 59
Engine top end 4 11 59
Muffler 59
Muffler removal 59
Piston piston pin 59
Piston rins end gap 59
Engine top eno 60
Muffler installation notes 60
Engine right side 61
Table of contents 61
Clutch 64
Clutch adjustment 64
Dutch adjustment check 64
Engine right side 64
Washing 64
Caihion 65
Clutch cable removal 65
Clutch cover installation note 65
Clutch cover removal 65
Clutch removal 65
Dutch release lever shaft installation note 65
Engine right side 5 5 65
6 engine right side 66
Caution 66
Clutch installation notes 66
Clutch spring free length measurement 67
Engine right side 5 7 67
Friction or steel plate warp inspection 67
Friction plate wear damage inspection 67
8 engine right side 68
Clutch housing finger inspection 68
Dutch hub spline inspection 68
Right engine cover 68
Right engine cover removal 68
Caution 69
Engine right side 5 9 69
Right engine cover installation 69
Engine right side 70
Kickstarter 70
Kickstarter installation notes 70
Kickstarter removal 70
Engine lubrication system 71
Table of contents 71
2 engine lubrication system 72
Exploded view 72
Engine lubrication system 74
Oh changing 74
Oh level inspection 74
Warn ims 74
Bleeding the oh pump 75
Engine lubrication system 6 5 75
Engine oil pump 75
Oil pump and carburetor synchronization 75
Synch roniza tion a djus men t 75
Synchronization inspection 75
6 engine lubrication system 76
Off pump check valve inspection 76
Oh pump performance test 76
Cautio 77
Engine lubrication system 6 7 77
Engine oil tank 77
Engine oil tank removal 77
Oh pump removal 77
Oil pump assembly caution 77
Oil pump installation notes 77
8 engine lubrication system 78
Cautio 78
Ou tank installation notes 78
Engine removal lnstallation 79
Table of contents 79
Engine removal installation 7 3 81
Engine removal instanation 81
Nstahation 81
Removal 81
Warnin 81
Crankshaft transmission 82
Table of contents 82
Crankshaft transmission 8 3 84
Crankcase assembly notes 86
Crankcase replacement 86
Crankcase splitting 86
Crankshaft transmission 8 5 86
Connecting rod big end radial clearance 87
Crankfhah connecting rod 87
Crankshaft installation notes 87
Crankshaft transmissiqn 87
Connecting hod big end seizure 88
Connecting hod big end side clearance 88
Crankshaft alignment 88
Crankshaft runout 88
Crankshaft transmission 8 7 88
Caution 89
Cran kshaft transmission 89
Externa shift mechanism installation notes 89
External shift mechanism removal 89
Shift pedal installation note 89
Transmission 89
C ran kshaft tr ansmission 8 9 90
Shift drum installation notes 90
Shift drum removal 90
Transmission shaft shift fork 90
Warming 90
10 crankshaft transmission 91
Transmission assembly notes 91
Transmission disassembly 91
Balancer 92
Balancer shaft installation 92
Balancer shaft removal 92
Crankshaft transmission 8 11 92
12 crankshaft transmission 93
Balancer cover replacement 93
Cautio 93
Table of contents 94
Wheels tîres 94
Exploded view 95
Wheels ures 95
Bead breaker fp n 57001 1072i 97
Special tools 97
Tire irons p n 5700 f 1073j sre included in the 97
Wheels tires 97
Cautionj 98
Front wheel installation notes 98
Front wheel removal 98
Wheels rims 98
Wheels tires 9 98
6 wheels tires 99
Rear wheel removal 99
Warning 99
Balance weight installation 100
Cautionj 100
Rear wheel installation notes 100
Wheel rim inspection 100
8 wheels tires 101
Balance weight removal 101
Tire air pressure inspection 101
Fiemovaf 102
Hub bearings 102
Tire fnstaftàtion 102
Tire inspection 102
Wheels tires 9 9 102
10 wheels tires 103
Cautio 103
Disassembly and assembly 103
Inspection 103
Installation 103
Lubrication 103
Speedometer gear housing 103
Final drive 104
Table of contents 104
2 final drive 105
Exploded view 105
Drive chain 107
Drive chain slack adjustment 107
Wheel alignment adjustment 107
Л final drive 107
Юл final drive 107
Drive chain installation notes 108
Drive chain removal 108
Drive chain wear inspection 108
Final drive 10 5 108
Warning 108
6 final drive 109
Caution 109
Drive chain lubrication 109
Engine sprocket installation notes 109
Engine sprocket removal 109
Sprocket coupling 109
Warning 109
Coupling bearing installation note 110
Coupling bearing lubrication 110
Final drive 10 7 110
Rear sprocket installation votes 110
Rear sprocket removal 110
Sprocket warp 110
Warming 110
Brakes 111
Table of contents 111
Brakes 11 3 113
Brake pedal 115
Brake pedal position adjustment 115
Brakes 11 5 115
Caliper 115
Front caliper removal 115
6 brakes 116
Assembly notes 116
Caliper insta flation notes 116
Disassembly notes 116
Rear caliper removal 116
Warning i 116
Brake pads 117
Brakes 11 7 117
Front master cylinder installation 117
Installation notes 117
Lining wear 117
Master cylinders 117
Removal 117
Torque link assembly note 117
Warning 117
8 brakes 118
Disassembly 118
Inspection and adjustment after installation 118
Note the following 118
Rear master cylinder installation 118
Rear master cylinder removal 118
Assembly 119
Brake disc 119
Brakes 11 9 119
From disc installation notes 119
Inspection visually i 119
Apply non permanent locking agent to the threads of 120
Brake di1c 120
Brake disc 2 measuring area 120
Brake disc mounting nuts front axle clamp bolts front 120
Brake fluid 120
Check the brake fluid level in the reservoir 120
Fluid level inspection 120
General information chapter 120
Ii runout exceeds the service limit replace the disc 120
Lower level line 2 lipper level 120
Measuring area 120
Nut brake caliper mounting bolts side stand bracket mounting bolts 120
Replace the disc if it has worn past the service limit 120
Side stand bracket mounting bolts 120
Tighten the following parts to the specified torque see 120
Tv10 brakes 120
Warning 120
Alter a clear plastic hose to the bleed valve on the 121
Brake fluid change 121
Brakes 11 11 121
Caliper and run the other end of rhe hose into a container 121
Change the brake fluid as fellows 121
Check the fluid level in the reservoir often replenishing 121
Fluid level 121
Follows changing the rear brake fluid is the sarne as for the front brake 121
Hold the reservoir horizontal when checking brake 121
I open the bleed valve 2 apply the brake and hold it 3 close the bleed valvp 4 release the brake lever 121
If the fluid in the reservoir runs completely out any 121
It as necessary 121
Lower level line 2 upper level line 121
On the bleed valve 121
Procedure to change the front brake fluid is as 121
Remove the reservoir cap and remove the rubber cap 121
Tf the fluid level is lower than the lower level line fill 121
The reservoir to the upper level line of the reservoir 121
Time during fluid changing the bleeding operation must be done over again from the beginning since air win have entered the line 121
Warning 121
12 brakes 122
Bleeding the brake line 122
Warning 122
Brakes 11 13 123
Warnin 123
Suspension 124
Table of contents 124
2 suspension 125
Exploded view 125
Front fork 127
Suspension 127
Warning 127
Suspension 12 5 128
6 suspension 129
Warning 129
Assembly notes 130
Guide bush inspection 130
Inner tube inspection 130
Suspension 12 7 130
8 suspension 131
I ii hl 131
Oh seal and dust seal inspection 131
Rear shock absorber 131
Rear suspension uni trak 131
Rebound damping force adjustment 131
Spring force adjustment 131
Spring tension 131
Suspension 12 9 132
Swing arm 132
Warning 132
10 suspension 133
Caution 133
Tie rod rocker arm 133
Warning j 133
Bearing lubrication 134
Needle bearing inspection 134
Rocker arm installation 134
Rocker arm removal 134
Suspension 12 11 134
Tie rod installation 134
Tie rod rocker arm needle 134
Tie rod rocker arm sleeve inspection 134
Steering 135
Table of contents 135
2 steering 136
Exploded view 136
Special tools 137
Steering 13 3 137
Steering 138
Steering stem 138
Warning 138
Installation 139
Steering 13 5 139
6 steering 140
Bearing lubrication 140
Bearing wear damage 140
Steering stem bearing 140
Steering stem warp 140
Stem cap deterioration damage 140
Table of contents 141
Fairings fender 144
Lower fairing installation note 144
Lower fairing removal 144
Rear fender front section removal 144
Rear fender rear section removal 144
Upper fairing removal 144
Frame 14 5 145
Seat cover 145
Seat cover installation 145
Electrical system 146
Table of contents 146
Electrical system 15 3 148
Precautions 148
Electrical system 149
Parts location 149
Australian and south african models 150
Bk r rk v 150
Electrical system 155 150
Kr250 b1 b2 wiring diagram 150
Küilüüh 150
Isiisi 151
Kr250b2 wiring diagram 151
Other than australian and south african models 151
Electrical system 15 8 154
Electrical system 15 10 156
Sealant 156
Special tools 156
The flywheel holder p n 57001 1313 can be used instead of the flywheel holder p n 57001 306 156
11 electrical system 157
Battery 157
Battery case the electrolyte level should be between the upper and the lower level lines 157
Battery needs to be charged 157
Electrolyte level inspection check the level with the electrolyte level gauge on the 157
Electrolyte specific gravity inspection check battery condition by testing the specific gravity 157
Fill each cell to the upper level line on the battery case 157
For example if the battery is rated at 12 ah the charging rate would be 1 a 157
If the level of electrolyte in any cell is below the lower 157
If the specific gravity is below 1 0 charge 60 the 157
Initial charging 157
Level line add only distilled water to cell until the level is at the upper level line 157
Of the electrolyte in each cell with a hydrometer 157
Olf the electrolyte level drops add electrolyte to the 157
Oread the level of the electrolyte on the floating scale 157
Read here 157
Set the charging rate at 1 10 the battery capacity and 157
Upper level line 2 lower level line 157
Upper level une before charging 157
Warning 157
With fresh electrolyte special gravity 1 80 at a temperature of 30 c 86 f or less let the battery stand for about 30 minutes before charging 157
A flywheel holder 57001 306 b rotor bolt 158
A flywheel puller 57001 252 b adapter 57001 1279 158
A mounting bolts b magneto cover 158
Charge until the electrolyte gravity becomes 1 80 ata temperature of 30 c 86 f or less 158
Charging system 158
Check the electrolyte level after charging 158
Electrical system 15 12 158
Flywheel from rotating unscrew the rotor bolt 158
Lower fairing 158
Magneto cover removal remove the following 158
Magneto rotor removal remove the magneto cover using the flywheel holder special tool to keep the 158
Ordinary charging 158
Set the charging rate at 1 10 the battery capacity and 158
Using the flywheel puller special tool and adapter special tool remove the magneto rotor 158
Warning 158
13 electrical system 159
Battery 159
Caution 159
Charging system wiring diagram 159
Flywheel can cause the magneto to lose their magnet ism 159
Ignition switch 2 6 pin connector 3 load 4 6 pin connector 5 stator coil 159
Magneto rotor installation notes using a high flash point solvent wash the tapered 159
Obe careful not to strike the flywheel itself striking the 159
Pin connector 7 regulator rectifier 8 20a fuse 9 6 pin connector 159
Portions of flywheel rotor and crankshaft 159
Seat side covers fuel tank 159
See general information chapter 159
Stator coil removal remove the magneto rotor remove the following 159
Tighten the magneto rotor bolt to the specified torque 159
Electrical system 15 14 160
15 electrical system 161
Caution 161
Electrical system 15 16 162
Ignition system 162
Safety instructions 162
Warning 162
17 electrical system 163
Electrical system 15 18 164
19 electrical system 165
Warning 165
Electrical system 15 20 166
21 electrical system 167
Electrical system 15 22 168
Lighting system 168
23 electrical system 169
Headlight bulb replacement notes 169
License plate light replacement notes 169
Tail brake light bulb 169
Wedge base type bulb replacement note 169
A connector b speedometer cable upper end 170
A mounting bolts b meter assembly 170
A triangular mark 170
Check the coolant temperature gauge circuit wiring 170
Coolant temperature gauge 170
Electrical system 15 24 170
Gauge and or wiring 170
If all wiring and components other than the coolant 170
In the housing so that the traiangular mark points down and turn it clockwise 170
Insert the socket by aligning the tangs with the catches 170
Lf these readings are not correct the trouble is with the 170
Lower fairing upper fairing 170
Meter gauge 170
Operation inspection 170
Prepare an auxiliary wire and check the operation of 170
Removal 170
Remove the following 170
See wiring inspection 170
Temperature gauge unit check out good the gauge is defective 170
The gauge 170
25 electrical system 171
Oh level warning light inspection 171
Rear brake light switch adjustment 171
Switches and sensors 171
Tachometer inspection 171
Caution 172
Coolant temperature sensor inspection 172
Electrical system 15 26 172
Installation note 172
Right and left switch housing 172
27 electrical system 173
Electrical system 15 28 174
Fuse box 174
Turn signal relay 174
Appendix 175
Table of contents 175
2 appendix 176
Additional considerations 176
Carburetors 176
For racing 176
Spark plug 176
Appendix 16 3 177
Spark plug inspection 177
Appendix 178
Engine doesn t start starting difficulty 178
Poor running at low speed 178
Poor running no power at high speed 178
Troubleshooting guide 178
Appendix 16 5 179
Fuel and oil consumption excessive 179
Overcooling 179
Overheating 179
6 appendix 180
Abnormal drive train noise 180
Abnormal engine noise 180
Abnormal frame noise 180
Clutch operation faulty 180
Exhaust smoke 180
Gear shift faulty 180
Appendix 16 7 181
Battery discharged 181
Battery overcharged 181
Brake doesn t hold 181
Handling and or stability unsatisfactory 181
8 appendix 182
General lubrication nut bolt and fastener tighteness 182

Kawasaki KR250 [3/183] General information

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