Kawasaki GPX250R (1987) [107/248] 4 engine removal installation

Содержание

• Quick reference guide 3
• Kawasaki 5
• Motorcycle 5
• Ninja250r gpx250r 5
• Service manual 5
• Supplement 5
• Read owner s manual before operating 6
• Emission control information 7
• Tampering with noise control system prohibited 8
• Foreword 9
• General information 13
• Table of contents 13
• General information 1 7 19
• 8 general information 20
• General information 1 9 21
• 10 general information 22
• Fuel system 29
• Fuel system 2 1 29
• Table of contents 29
• Fuel system 2 3 31
• A throttle grip free play 32
• Along with common hand tools the following more 32
• Check throttle grip free play by lightly turning the 32
• Fuel system 32
• If the throttle grip free play is incorrect adjust the 32
• Special tools 32
• Specialized tools are required for complete fuel system servicing 32
• Specifications 32
• Throttle cables 32
• Throttle grip and cable 32
• Throttle grip back and forth 32
• Throttle grip play inspection 32
• Air cleaner 33
• Air cleaner element installation 33
• Air cleaner element removal 33
• Cautjôïï 33
• Fuel system 2 5 33
• Warning 33
• Choke cable 34
• Choke cable free play inspection 34
• Fuel system 2 5 34
• Throttle cable adjustment 34
• Throttle cable inspection 34
• Throttle cable lubrication 34
• Carburetors 35
• Choke cable adjustment 35
• Choke cable inspection 35
• Choke cable lubrication 35
• Fuel system 2 5 35
• Idle speed inspection 35
• Carburetor synchronization 36
• Carburetor synchronization inspection 36
• Fuel system 2 5 36
• Idle speed adjustment 36
• Warning 36
• Fuel level adjustment 37
• Fuel level inspection 37
• Fuel system 2 5 37
• Warning 37
• Carburetor assembly removal 38
• Fuel system 2 5 38
• Fuel system cleanliness inspection 38
• Warning 38
• Carburetor assembly installation notes 39
• Carburetor installation 39
• Carburetor separation 39
• Caution 39
• Fuel system 2 5 39
• Warning 39
• Warning i 39
• Carburetor disassembly and assembly notes 40
• Caution 40
• Fuel system 2 5 40
• Fuel system 2 5 41
• Îcaut 41
• Carburetor cleaning 42
• Carburetor inspection 42
• Caution 42
• Fuel system 2 5 42
• Warn in 42
• Warning j 42
• Fuel system 2 5 43
• Air cleaner 44
• Air cleaner element installation 44
• Air cleaner element removal 44
• Cautio 44
• Fuel system 2 5 44
• Warming 44
• Air cleaner element cleaning 45
• Air cleaner element inspection 45
• And replacement 45
• B lea th er oh inspection 45
• Caution 45
• Fuel system 2 15 45
• Fuel tank 45
• Fuel tank removal 45
• Warnin 45
• Warning i 45
• Fuel system 2 5 46
• Fuel tank and cap inspection 46
• Fuel tank and tap cleaning 46
• Fuel tap inspection 46
• Warning 46
• Canister inspection 47
• Evaporative emission control system 47
• Fuel system 2 5 47
• Hose inspection 47
• I cauti onf 47
• Parts removal installation notes 47
• Separator inspection 47
• Separator operation test 47
• Us california vehicle only 47
• Warning 47
• Warning i 47
• Fuel system 2 19 48
• Cooling system 49
• Cooling system 3 1 49
• Table of contents 49
• Cooling system 50
• Exploded view 50
• Coolant 52
• Coolant deterioration 52
• Coolant level inspection 52
• Cooling system 52
• System controls the engine temperature within narrow limits where the engine operates most efficiently in this way the engine performs stably in various riding conditions and is very durable 52
• The water cooling system is a pressurized forced circulation type when the engine load varies this 52
• 6 cooling system 53
• Air bleeding 53
• Caution 53
• Visual leak inspection 53
• Caution 54
• Cooling system 3 7 54
• Disassembly and assembly precautions 54
• Flushing 54
• Pump cover installation note 54
• Pump cover removal 54
• Water pump 54
• 8 cooling system 55
• Pump impeller inspection 55
• Radiator radiator fan 55
• Radiator radiator fan removal 55
• Warning 55
• Water pump installation notes 55
• Water pump removal 55
• Cooling system 3 9 56
• Radiator inspection 56
• Radiator installation note 56
• 10 cooling system 57
• Radiator cap inspection 57
• Radiator cleaning 57
• 12 cooling system 58
• 5 83 c 177 182 f 58
• Thermostat inspection 58
• Thermostatic fan switches water temperature sensor 58
• Water temperature sensor removal 58
• Cooling system 3 13 59
• Fan switch removal 59
• Inspection 59
• Installation note 59
• Engine top end 60
• Engine top end 4 1 60
• Table of contents 60
• Engine top end 4 3 62
• Engine top end 4 5 64
• Refer to the base manual noting the following 64
• Sealant 64
• Special tools 64
• 6 engine top end 65
• Cylinder head cover 65
• Cylinder head cover installation notes 65
• Cylinder head cover removal 65
• Camshaft camshaft chain rocker arm 66
• Camshaft chain tensioner 66
• Camshaft chain tensioner assembly 66
• Camshaft chain tensioner disassembly 66
• Camshaft rocker arm removal 66
• Caution 66
• Chain tensioner installation 66
• Chain tensioner removal 66
• Engine top end 4 7 66
• Camshaft installation 68
• Engine top end 4 9 68
• Including chain timing procedure 68
• 10 engine top end 69
• Camshaft and sprocket assembly notes 69
• Camshaft oil clearance inspection 69
• Fcaution 69
• Camshaft chain guide wear 70
• Camshaft chain wear 70
• Compression measurement 70
• Cylinder head 70
• Engine top end 4 11 70
• Z 1 0 0 o o o j 70
• Z vvvz 70
• 12 engine top end 71
• Cylinder head installation notes 71
• Cylinder head removal 71
• Cylinder head disassembly and assembly 72
• Engine top end 4 13 72
• Valve mechanism removal and installation 72
• 14 engine top end 73
• Cylinder head cleaning 73
• Cylinder head warp 73
• 8 engine top end 74
• Valve clearance adjustment 74
• Engine top end 4 9 75
• Valve seat inspection 75
• Engine top end 4 17 76
• Valve seat repair 76
• Engine top end 4 19 77
• Measuring vaive to guide clearance 77
• Wobble method 77
• Cylinder installation notes 79
• Cylinder piston 79
• Cylinder removal 79
• Engine top end 4 21 79
• Piston removal 79
• 22 engine top end 80
• Caution 80
• Piston installation note 80
• Cylinder inside diameter 81
• Engine top end 4 23 81
• Piston ring end gap 81
• Piston ring piston ring groove wear 81
• Cautio 82
• Engine top end 4 25 82
• Muffler 82
• Muffler installation 82
• Muffler removal 82
• Warning 82
• Clutch 84
• Table of contents 84
• Clutch 85
• Clutch 87
• Clutch adjustment 87
• Clutch adjustment check 87
• Warning i 87
• Clutch 5 5 88
• Clutch cover installation note 88
• Clutch cover removal 88
• Clutch release lever shaft installation note 88
• Clutch release lever shaft removal 88
• 6 clutch 89
• Clutch installation notes 89
• Clutch removal 89
• Caution 90
• Clutch 5 7 90
• Friction or steel plate warp inspection 90
• Friction plate wear damage inspection 90
• Clutch 92
• Clutch housing finger inspection 92
• Clutch hub spline inspection 92
• Clutch spring free length measurement 92
• Engine lubrication system 93
• Table of contents 93
• 2 engine lubrication system 94
• Exploded view 94
• Engine lubrication system 6 3 95
• Engine oil flow chart 95
• Caution 98
• Cautjon 98
• Engine lubrication system 98
• Engine oh and or filter change 98
• Engine oh level inspection 98
• Engine oil and filter 98
• Warning 98
• Bypass valve assembly 99
• Bypass valve cleaning and inspection 99
• Bypass valve disassembly 99
• Engine lubrication system 6 7 99
• Oil filter and mounting bolt installation notes 99
• Oil filter and mounting bolt removal 99
• Relief valve removal 99
• Warning 99
• Engine lubrication system 100
• Oh pump assembly note 100
• Oh pump installation notes 100
• Oil pressure measurement 100
• Oil pump 100
• Oil pump removal 100
• Ou pump disassembly 100
• Retief valve installation note 100
• Engine lubrication system 6 9 102
• Oh pump inspection 102
• Relief valve inspection 102
• Warming 102
• Warning 102
• Engine removal lnstallation 104
• Table of contents 104
• 2 engine removal installation 105
• Exploded view 105
• Hihh ml 105
• Othis tool may be used instead of the common tool 105
• Special tool 105
• Engine removal 106
• Engine removal installation 7 3 106
• Engine removal lnstallation 106
• 4 engine removal installation 107
• Engine installation 107
• Crankshaft transmission 108
• Crankshaft transmission 8 1 108
• Table of contents 108
• Cran kshaft tr ansmission 8 3 110
• 26 00 mm 112
• 29 08 mm 112
• 29 16 mm 112
• Balancer shaft 112
• Balancer shaft bearing bore diameter 29 00 29 16 mm 112
• Balancer shaft bearing insert 112
• Balancer shaft bearing insert selection 112
• Balancer shaft journal diameter 25 84 26 00 mm 25 6 mm 112
• Cran kshaft tr ansmission 8 5 112
• Crankshaft main bearing insert selection 112
• Crankshaft side clearance 0 5 0 0 mm 0 0 mm 112
• Gear backlash 0 0 7 mm 0 5 mm 112
• Gear shift fork groove width 5 5 5 5 mm 5 mm 112
• Item standard service limit 112
• Journal clearance 0 20 0 44 mm 0 8 mm 112
• Marking none 112
• None marking 25 84 25 92 mm 112
• Shift drum groove width 6 5 6 0 mm 6 mm 112
• Shift fork ear thickness 4 5 mm 4 mm 112
• Shift fork guide pin diameter 5 6 mm 5 mm 112
• Special tools 112
• Transmission 112
• 6 crankshaft transmission 113
• Crankcase splitting 113
• Cautio 114
• Caution 114
• Crankcase assembly 114
• Crankshaft transmission 8 7 114
• 8 crankshaft transmission 115
• Crankcase exchange 115
• Crankshaft connecting rods 116
• Crankshaft installation notes 116
• Crankshaft removal 116
• Crankshaft transmission 8 9 116
• 10 crankshaft transmission 117
• Caution 117
• Connecting rod bend 117
• Connecting rod installation notes 117
• Connecting rod removal 117
• Crankshaft connecting rod cleaning 117
• Connecting rod big end bearing 118
• Connecting rod big end side clearance 118
• Connecting rod twist 118
• Crankshaft transmission 8 11 118
• Insert crankpin wear 118
• 12 crankshaft transmission 119
• Crankshaft runout 119
• Crankshaft main bearing insert journai wear 120
• Crankshaft transmission 8 13 120
• 14 crankshaft transmission 121
• Crankshaft side clearance 121
• Balancer 122
• Balancer installation notes 122
• Balancer removal 122
• Balancer shaft bearing insert journal wear 122
• Crankshaft transmission 8 15 122
• Crankshaft transmission 123
• Starter motor clutch 123
• Starter motor clutch removal 123
• Crankshaft transmission 8 17 124
• External shift mechanism removal 124
• External shift mechanism removal note 124
• Starter motor clutch assembly note 124
• Starter motor clutch disassembly 124
• Starter motor clutch inspection 124
• Starter motor clutch installation notes 124
• Transmission 124
• 18 crankshaft transmission 125
• Externa shift mechanism inspection 125
• External shift mechanism installation notes 125
• Crankshaft transmission 8 19 126
• Drive shaft assembly notes 126
• Drive shaft disassembly 126
• Output shaft disassembly 126
• Transmission shaft installation 126
• Transmission shaft removal 126
• 20 crankshaf17transmission 127
• Output shaft assembly notes 127
• Shift drum and fork removal 127
• Crankshaft transmission 8 21 128
• Shift drum and fork installation 128
• 22 crankshaft transmission 129
• Gear backlash 129
• Shift drum assembly notes 129
• Shift drum disassembly note 129
• Crankshaft transmission 8 23 130
• If a gear shift fork groove is worn over the service limit 130
• If any shift drum groove is worn over the service limit 130
• If the guide pin on any shift fork is less than the service 130
• Lf the thickness of a shift fork ear is less than the 130
• Limit the fork must be replaced 130
• Measure the diameter of each shift fork guide pin and 130
• Measure the thickness of the shift fork ears and 130
• Measure the width of each shift drum groove 130
• Measure the width of the shift fork grooves on the transmission gears 130
• Move back and forth lightly 2 hold steady 130
• Service limit the shift fork must be replaced 130
• Shift fork bending 130
• Shift fork ears 3 shift fork 2 shift fork guide pin 130
• Shift fork gear groove wear 130
• Shift fork guide pin shift drum groove wear 130
• That is bent a bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power 130
• The drum must be replaced 130
• The gear must be replaced 130
• Visually inspect the shift forks and replace any fork 130
• 24 crankshaft transmission 131
• Ball and needle bearing wear 131
• Gear dog gear dog hole damage 131
• Table of contents 133
• Wheels tires 133
• 2 wheels tires 134
• Front wheel installation 136
• Front wheel removal 136
• Rear wheel removal 136
• Warning 136
• Wheels rims 136
• Wheels tires 136
• Rear wheel installation 137
• Warning 137
• Wheel inspection 137
• Wheels tires 95 137
• 6 wheels tires 138
• Axle inspection 138
• Ivhee balance 138
• Warning 138
• Tire removal 139
• Wh e e ls tir es 9 7 139
• 8 wheels tires 140
• Tire installation 140
• 10 wheels tires 141
• Cautio 141
• Front hub bearing removal 141
• Hub bearings 141
• Tire inspection 141
• Tire repair 141
• Warning j 141
• Front hub bearing installation 142
• Wheels tires 9 11 142
• 12 wheels tires 143
• Hub bearing inspection and lubrication 143
• Rear hub bearing installation 143
• Rear hub bearing removal 143
• Grease seal inspection and lubrication 144
• Speedometer gear housing 144
• Speedometer gear housing assembly 144
• Speedometer gear housing disassembly 144
• Wheels tires 9 13 144
• Final drive 147
• Table of contents 147
• 2 final drive 148
• 4 final drive 150
• Drive chain 150
• Drive chain slack adjustment 150
• Drive chain stack inspection 150
• Warning 150
• Drive chain wear inspection 151
• Final drive 10 5 151
• Warning 151
• Warning j 151
• Wheel alignment adjustment 151
• Wheel alignment inspection 151
• 6 final drive 152
• Drive chain lubrication 152
• Drive chain removal 152
• Icautionl 152
• Warning j 152
• Caution 153
• Drive chain installation 153
• Engine sprocket installation 153
• Engine sprocket removal 153
• Final drive 10 7 153
• Rear sprocket coupling removal 153
• Sprocket coupling 153
• 8 final drive 154
• Rear sprocket coupling installation 154
• Sprocket warp 154
• Sprockets wear 154
• Coupling bearing inspection and lubrication 155
• Coupling bearing installation 155
• Coupling bearing removal 155
• Final drive 10 9 155
• 10 final drive 156
• Damper inspection 156
• Grease seal inspection and lubrication 156
• Brakes 157
• Brakes 11 1 157
• Contents 157
• Table of 157
• Brake adjustment 160
• Brake pedai position inspection 160
• Brake pedal position adjustment 160
• Brakes 160
• Front brake 160
• Rear brake 160
• Brakes 11 5 161
• Caliper assembly notes 161
• Caliper disassembly notes 161
• Caliper installation notes 161
• Calipers 161
• Front caliper removal 161
• Rear caliper removal 161
• Warning 161
• 6 brakes 162
• Brake pad removal 162
• Brake pads 162
• Caliper holder shaft wear 162
• Dust seal and cover damage 162
• Fluid seal damage 162
• Piston cylinder damage 162
• B brakes 163
• Cautj0fi 163
• Front master cylinder disassembly notes 163
• Inspection and adjustment after installation 163
• Rear master cylinder installation notes 163
• Rear master cylinder removal 163
• Brakes 11 9 164
• Cautio 164
• Caution 164
• Front master cylinder assembly notes 164
• Master cylinder inspection 164
• Rear master cylinder assembly notes 164
• Rear master cylinder disassembly notes 164
• Visual inspection 164
• 10 brakes 165
• B mounting bo 165
• Disc wear 165
• Reservoir installation notes 165
• Reservoir removal 165
• Brake fluid 166
• Brake fluid change 166
• Brakes 11 11 166
• Change the brake fluid the brake fluid should also be changed if it becomes contaminated with dirt or water 166
• Chotd the reservoir horizontal when checking brake 166
• Disc cleaning 166
• Disc warp 166
• Fluid level 166
• Fluid level inspection 166
• If the fluid level is lower than the lower level line fill the reservoir to the upper level une of the reservoir 166
• In accordance with the periodic maintenance chart 166
• Inspect the brake fluid level in the front and rear brake fluid reservoirs check the brake fluid level in the reservoir 166
• Jack up the motorcycle so that the front wheel is off 166
• Lower level line 2 upper level line 166
• Poor braking can be caused by oil on the disc oil on 166
• The disc must be cleaned off with an oil less cleaning fluid such as trichloroethylene or acetone 166
• The fluid level must be kept above the lower level lines 166
• The ground and turn the handlebar fully to one side set up a dial gauge against the front disc and measure disc runout remove the jack set the motorcycle up on its center stand and then measure the rear disc runout if runout exceeds the service limit replace the disc 166
• Warning 166
• Warning j 166
• 12 brakes 167
• Bleeding the brake line 167
• Brake hose 168
• Brake hose inspection 168
• Brakes 11 13 168
• J warning 168
• 14 brakes 169
• Brake hose replacement 169
• Suspension 171
• Table of contents 171
• 2 suspension 172
• Caution 173
• Fork oh change 173
• Front fork 173
• Front fork removal each fork leg 173
• Specifications 173
• Suspension 12 3 173
• 4 suspension 174
• Front fork disassembly 174
• Front fork installation each fork leg 174
• Caution 175
• Front fork assembly 175
• Inner tube inspection 175
• Suspension 12 5 175
• 6 suspension 176
• Guide bush inspection 176
• Oh seal and dust seal inspection 176
• Rear shock absorber rear shock absorber adjustment 176
• Rear shock absorber removal 176
• Rear suspension uni trak 176
• Spring tension 176
• 8 suspension 178
• Swing arm installation notes 178
• Swing arm needle bearing inspection 178
• Swing arm needle bearing lubrication 178
• Swing arm sleeve inspection 178
• Tie rod rocker arm tie rod removal 178
• Cautio 179
• Rocker arm installation notes 179
• Rocker arm removal 179
• Suspension 12 9 179
• Tie rod installation note 179
• Tie rod rocker arm bushing inspection 179
• Tie rod rocker arm bushing lubrication 179
• Tie rod rocker arm sleeve inspection 179
• Steering 181
• Table of contents 181
• 2 steering 182
• Exploded view 182
• Handlebar 183
• Handlebar holder installation notes 183
• Special tools 183
• Steering 13 3 183
• 4 steering 184
• Steering adjustment 184
• Steering inspection 184
• Bearing wear damage 185
• Steering 13 5 185
• 6 steering 186
• Steering maintenance 186
• Steering stem bearing lubrication 186
• Bearing wear damage 187
• Grease sea deterioration damage 187
• Steering 13 7 187
• Steering stem warp 187
• Table of contents 189
• 2 frame 190
• 4 frame 192
• Caution 192
• Sear installation 192
• Seat removal 192
• Side cover removal 192
• Side covers 192
• Caution 193
• Fairings 193
• Frame 14 5 193
• Lower fairing removal 193
• Upper fairing installation notes 193
• Upper fairing removal 193
• 6 frame 194
• Fenders 194
• Front part of rear fender removal 194
• Rear part of rear fender removal 194
• Seat cover removal 194
• Upper fairing stay removal 194
• Footpeg bracket 195
• Frame 14 7 195
• Front part of rear fender installation 195
• Left footpeg bracket installation note 195
• Left footpeg bracket removal 195
• Right footpeg bracket removal 195
• Electrical system 197
• Electrical system 15 1 197
• Table of contents 197
• 2 electrical system 198
• Precautions 198
• 2 electrical system 199
• Exploded view 199
• Electrical system 15 3 200
• Electrical system 201
• Parts locations 201
• Additional tools 202
• C 176 f 42 62 q 202
• C 212 f 22 33 i2 202
• Electrical system 15 5 202
• Ousc the coil tester instead of kawasaki electrotestcr 202
• Pn 57001 980 202
• Refer to the base manual noting the following 202
• Sealant 202
• Special tools 202
• Specifications 202
• Water temperature sensor resistance 202
• Battery 203
• Battery charging battery condition 203
• Electrical system 15 9 203
• Electrolyte electrolyte level inspection 203
• Precautions 203
• 10 electrical system 204
• Battery initial chargins 204
• Battery ordinary charging 204
• Cauti0n 204
• Caution 204
• Remove the battery from the motorcycle 204
• Warning 204
• Warning j 204
• Battery test charging 205
• Caut10 n 205
• Electrical system 15 11 205
• 12 electrical system 206
• A rotor puller 206
• Alternator cover installation note 206
• Alternator cover removal 206
• Alternator rotor installation notes 206
• Alternator rotor removal 206
• Cautio 206
• Charging system 206
• Alternator inspection 207
• Electrical system 15 13 207
• Stator coil installation notes 207
• Stator coil removal 207
• Warning i 207
• 14 electrical system 208
• Rectifier inspection 208
• Caution 209
• Electrical system 15 15 209
• Regulator inspection 209
• 16 electrical system 210
• Ignition system 210
• Regulator rectifier output voltage inspection 210
• Safety instructions 210
• Warning i 210
• Electrical system 15 17 211
• Pickup coil installation 211
• Pickup coil removal 211
• Spark plug installation notes 211
• Spark plug removal 211
• 18 electrical system 212
• Ignition coil removal 212
• Connect g or bk lead 213
• Electrical system 15 19 213
• Ignition coil inspection 213
• Ignition coil installation notes 213
• Pickup coil inspection 213
• Warning 213
• 20 electrical system 214
• Caution 214
• Ic igniter removal 214
• Spark plug cleaning inspection 214
• Spark plug gap 214
• Caution 215
• Caution j 215
• Electrical system 15 21 215
• Ic igniter inspection 215
• Ic igniter installation note 215
• Electric starter system 217
• Electrical system 15 23 217
• Starter motor disassembly 217
• Starter motor installation notes 217
• Starter motor removal 217
• 24 electrical system 218
• Starter motor assembly 218
• Electrical system 15 25 219
• 26 electrical system 220
• Armature inspection 220
• Brush inspection 220
• Brush spring inspection 220
• Commutator cleaning and inspection 220
• Brush leads inspection 221
• Brush plate and terminal bolt inspection 221
• Caution 221
• Electrical system 15 27 221
• Headlight beam horizontal adjustment 221
• Lighting system 221
• Starter relay inspection 221
• 28 electrical system 222
• Headlight beam vertical adjustment 222
• Healight bulb replacement notes 222
• Electrical system 15 29 223
• License plate light bulb replacement notes 223
• Removal installation note 223
• Tai brake isight bulb replacement notes 223
• Tai brake light lens 223
• Turn signal light bulb replacement note 223
• 30 electrical system 224
• Inspection 224
• Cooling fan system 225
• Electrical system 15 31 225
• Fan inspection 225
• Fan relay inspection 225
• Fan system circuit inspection 225
• 32 electrical system 226
• Meters and gauge 226
• Meters and gauge removal 226
• Bulb replacement notes 227
• D bk y 227
• Electrical system 15 33 227
• Meter and gauge assembly note 227
• Meter or gauge replacement 227
• Meters and gauge disassembly 227
• Tachometer inspection 227
• 34 electrical system 228
• Caution 228
• Water temperature gauge operation inspection 228
• Cautíofj 229
• Electrical system 15 35 229
• Front brake light testing 229
• Push on 229
• Rear brake light switch position adjustment 229
• Rear brake light testing 229
• Switch inspection 229
• Switch removal note 229
• Switches and sensors 229
• 36 electrical system 230
• Fan switch inspection 230
• Electrical system 15 37 231
• Fuse removal 231
• Junction box 231
• Water temperature sensor inspection 231
• 38 electrical system 232
• Caution 233
• Connection 233
• Diode circuit inspection 233
• Electrical system 15 39 233
• Electrical wiring 233
• Fan starter circuit and 233
• Fuse inspection 233
• Headlight relay inspection 233
• Junction box fuse circuit inspection 233
• Wiring inspection 233
• 40 electrical system 234
• Bk v cj bk y 235
• Bl h bk y br w y 235
• Bl r bk y br 235
• Ex250 f2 wiring diagram 235
• Gy g br bk y 235
• Oo j e 235
• R bk r v 235
• R bk r y 235
• Turn signal switch 235
• Us and canada models 235
• W 8l t 235
• Bk y öl 236
• Bk ÿ bl r r 236
• Cooling far 236
• Electrical system 15 17 236
• G ik y 236
• Lg bl r w bl 236
• Pickup coil 236
• Spark plugs 236
• Tail brake light 236
• Tur signal relay 236
• V 8 77 w 236
• W bl y g w 236
• 18 electrical system 237
• Ex250 f2 wiring diagram 237
• I u tj o s2 o 237
• Uk and australia models 237
• Uk model 238
• Appendix 239
• Table of contents 239
• 2 appendix 240
• Additional considerations for racing 240
• Carburetor 240
• Spark plug 240
• Spark plug inspection 240
• Appendix 16 3 241
• Engine doesn t start starting difficulty 241
• Plug reach 241
• Troubleshooting guide 241
• 4 appendix 242
• Poor running at low speed 242
• Poor running or no power at high speed 242
• Abnormal engine noise 243
• Appendix 16 5 243
• Clutch operation faulty 243
• Gear shifting faulty 243
• Over cooling 243
• Overheating 243
• 6 appendix 244
• Abnormal drive train noise 244
• Abnormal frame noise 244
• Brake doesn t hold 244
• Exhaust smokes excessively 244
• Handling and or stability unsatisfactory 244
• Oil pressure warning light goes on 244
• Appendix 16 7 245
• Battery discharged 245
• Battery overcharged 245
• General lubrication 245
• Lubrication 245
• Nut bolt and fastener tightness 245
• Tightness inspection 245
• I i i i i 246
• Heavy industries ltd 248
• Kawasaki 248
• Model application 248
• Part no 99924 1109 51 248
• Printed in japan 248

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7 4 ENGINE REMOVAL INSTALLATION Remove the engine mounting bolts Support the engine before sliding out the engine mounting bolts A Engine Brackts B Jack A Engine Mounting Bolts oRoutc the wiring harness eorrectory see Wiring Routing in General Information chapter Engine Installation Engine installation is the reverse of removal Pay attention to the following item olnsert the lower engine mounting bolt first while supporting the engine Then insert the upper mounting bolt and tighten the nuts loosely A Upper Mounting Bolt B Lower Mounting Bolt Before tightening the mounting bolts install the engine brackets When inserting the front engine mounting bolt use a jack under the engine to lift the engine