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KH250 (1972-1976)
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Kawasaki KH250 (1972-1976) [3/129] Foreword

Kawasaki KH400 (1974-1976) [3/129] Foreword

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Kawasaki 1
Kh s series 1
S series shop manual 1
Shop mahuàl 1
Foreward 3
Foreword 3
European model 4
Model application 4
Veer model begin frame no i major changes 4
Table of contents 5
General 6
I specifications 6
Specifications 6
Kh250 a5 8
Performance curves 8
Construction 11
Engine general maintenance 11
Ii engine general maintenance 11
Minor disassembly 11
Engine removal 12
Engine adjustments 14
Engine mounting 14
Idling adjustment 14
Starter lever adjustment 16
Clutch adjustment 17
Oil pump adjustment 17
Shift linkage adjustment 18
Shift pedal linkage adjustment 18
Air cleaner 19
Engine detailed maintenance 19
Iii engine detailed maintenance 19
Cylinder cylinder head 20
Piston piston pin 23
Piston rings 26
Engine left side 27
Disassembly c d ignition 28
System model 28
Right cover 30
Clutch clutch release 31
Overhaul 31
Primary gear 35
External gear shift mech 36
Operation 37
Crankcase 39
Crankshaft 41
Transmission 43
Operation 44
Kick starter 47
Lubrication system 49
Oil pump 49
Inspection and adjustment 51
Carburetors 52
Construction 58
Jv frame 58
Swing arm 59
Wheels 61
Inspection 65
Assembly 66
Hubs brakes sprocket 66
J construction 66
Table 28 rim runout 66
Table 29 front hub 66
A bearing and oil seal arc pressed into the 68
And the coupling on the left side the rear brake drum which is of the same construction as the front drum fits against the coupling separated by rubber shock dampers that buffer torque changes 68
B rear hub 68
Brake mechanism brake panel brake shoes the sprocket which receives engine power and turns the rear wheel and the coupling the brake panel is mounted on the right side of the brake drum 68
Coupling and the sprocket is bolted against it 68
Rear brake drum assembly 68
Rear hub mechanism 68
Table 30 rear hub 68
The rear hub consists of the brake drum rear 68
Disassembly 69
Brake lining measurement 70
Overhaul 70
Service limit 70
Second cam play 73
Assembly notes 74
Disassembly 74
Front wheel 74
Front wheel and brake 74
Front wheel on disc brake 74
Installation notes 74
Models disc brake brake lining wear indicator 74
Removal 74
Axje don t hold the axle instead otherwise tire speedometer gear drive will be damaged 75
C front brake lever adjustment 75
Die adjusting bolt a fraction of a turn so that the lever has less uian 75
During use and if it needs additional adjustment parts are probably excessively worn or defective 75
Hay in the brake lever can be adjusted oqt to 75
Hold the gear box stationary and screw in the 75
Inch 5 mm play and tighten the lock nut 2 align the parts as illustrated 75
Keep the lever from vibrating but a small amount of play must be left in to ensure a full braking stroke 75
The front brake itself is adjusted automatically 75
To adjust lever play loosen die lock nut turn 75
A disc brake disassembly 76
B brake pads see caution removal remove the front wheel pg 72 76
Brake fluid will damage painted surfaces any 76
Brake parts mountings are as follows 76
Caution 1 use only disc brake fluid isopropyl alcohol or 76
Disc brake 76
Do not use gasoline motor oil or any other 76
Ethyl alcohol for cleaning brake parts but do not allow rubber parts to remain in contact with these fluids for a long period of time 76
If any of the brake line fittings or the bleeder 76
Mineral oils near disc brake parts these oils cause deterioration of rubber brake parts if oil spills on any brake parts it is very difficult to wash off and will eventually reach and break down the rubber 76
Prescribed torque values for tightening disc 76
Spilled fluid should be wiped off immediately 76
Table 36 disc brake torque 76
Valve is loosened at any time the al r must be bled from the brake pg 80 76
Assembly notes 77
Assembly note 78
Installation note 78
Removal 78
Master cylinder 79
Caliper assembly 80
Bleeding the brake 81
Brake fluid 81
Braking release stroke 81
Braking stroke 81
Changing the brake fluid 81
Warning 82
Caliper parts wear 83
Master cylinder parts wear 83
Brake lining wear indicator 84
Brake une damage 84
Disassembly 84
Disc wear warp 84
From 74 models 84
Handlebars 84
Handlebars 1 construction 84
Handlebar assembly 85
Inspection 86
Adjustment 87
Assembly 87
Construction operation 87
Front fork drum brake models 87
Front fork on drum brake 87
Front shock absorber 87
Models steering stem 87
Disassembly 89
Inspection 91
Steering stem 91
Assembly 92
Bearing balls 92
Disassembly 94
Front fork 94
Front fork disc brake models 94
Front fork maintenance 94
Front fork on disc brake models 94
Front spring force 94
Assembly notes 96
Compression stroke 96
Extension stroke 96
Spring tension 96
Fork oil 97
Inner tube damage 97
Tabic 45 fork spring free length 97
Tabic 46 fork oil 97
Disassembly 98
Inspection 98
Operation 98
Rear shock absorbers 98
Rear shock absorbers 1 construction 98
Adjustment 99
Rear shock absorber 99
Construction operation 100
Drive chain 100
Inspection adjustment 100
No of links type 100
Table 47 chain specifications 100
Construction 101
Disassembly assembly 101
Fuel oil tanks 101
Disassembly 102
Assembly 103
Stands foot rests 103
Assembly 104
Construction 104
Inspection 104
Mufflers exhaust pipes 104
Mufflers exhaust pipes 1 construction 104
Removal 104
Assembly 106
Inspection 106
Removal 106
Ac generator rectifier 107
Armature winding connection 107
Electrical contact breaker models 107
I ac generator rectifier 1 construction and operation 107
V electrical 107
Inspection 108
2 zener diode 109
General 109
Operation 109
Thyristor 109
Voltage regulator 109
Inspection 110
Caution 111
Construction 111
Ignition system 111
Inspection 111
Operation 111
Ignition timing adjustment 112
Ac generator 113
Construction and operation 113
Electrical 113
Electrical cdi models 113
Inspection 113
Construction and operation 114
Inspection 114
Rectifier 114
Caution 115
Construction and operation 115
Regulator 115
Thyristor 115
Zener diode 115
Inspection 116
Capacitor discharge ignition 117
Ignition timing detection 117
C d i unit 118
Capacitor charge circuit 118
Inspection 119
Engine 120
Jllbluc cdiuurclul 120
Starting difficulty or failure to start 120
Troubleshooting 120
Vii troubleshooting 120
Engine misfires rotation unstable 121
Engine starts but stops right away 121
Low output power 122
Abnormal engine 123
Gear shift trouble 123
Sounds 123
A w w a w xz a w w 124
Absorbing bad 124
Clutch ________ 124
Control w 124
Malfunction 124
Poor steering 124
Shock _______ 124
U xz i v u 124
______ cknc _____________ 124
Periodic maintenance chart 125
Periodic maintenance guide 125
Torque specifications 126
Torque table 126
S x xs xx x xx 127
Toque for the bolts 127

Kawasaki KH250 (1972-1976) [3/129] Foreword

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