1992-2000 Kawasaki KX250 Clymer Motorcycle Repair Manual

Description

This 1992-2000 Kawasaki KX250 Motorcycle Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1992 1993 1994 1995 1996 1997 1998 1999 2000 Kawasaki KX250 motorcycles.

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 392 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Cleaning parts / Handling gasoline safely / Service hints / Serial numbers / Warning labels / Torque specifications / Fasteners / Lubricants / Sealant, cements and cleaners / Threadlocking compound / Basic hand tools / Precision measuring tools / Test equipment / Special tools / Mechanic’s tips / Ball bearing replacement / Seals

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Starting difficulties / Engine performance / Engine / Engine noises / Leak down test / Fuel system / Electrical troubleshooting / Test equipment / Ignition system / Clutch / External shift mechanism and transmission / Kickstarter / Drive train noise / Front suspension and steering / Rear suspension / Frame noise / Brakes

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals / Tune-up / Pre-ride inspection / Engine lubrication / Transmission oil / Air filter / Spark plug / Carburetor / Exhaust system / Cooling system / Engine compression check / Ignition timing / Control cable lubrication / Throttle cable adjustment / Clutch / Engine top end inspection / Kick pedal and shift pedal / Brakes / Drive chain and sprockets / Tires and wheels / Wheel bearings / Steering / Front fork / Rear shock absorber / Rear swing arm and linkage / General lubrication / Nuts, bolts and other fasteners / Storage

CHAPTER FOUR / ENGINE TOP END
Engine operating principles / Cleanliness / Exhaust system / Cylinder head / Cylinder / Exhaust valve / Exhaust valve service (1992) / Exhaust valve service (1993-on) / Exhaust valve cleaning and decarbonizing / Piston, piston pin and piston rings / Reed valve assembly / Engine break-in

CHAPTER FIVE / ENGINE BOTTOM END
Servicing engine in frame / Engine / Countershaft seal replacement / Left side main bearing seal replacement / Crankcase and crankshaft / Transmission shifting check

CHAPTER SIX / CLUTCH
Clutch cover / Clutch release arm / Right crankcase cover / Exhaust valve governor / Clutch / Clutch service / Water pump and primary drive gears / Kickstarter and idle gear / External shift mechanism / Clutch cable replacement

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission troubleshooting / Transmission / Transmission overhaul / Transmission inspection / Internal shift mechanism

CHAPTER EIGHT / FUEL SYSTEM
Carburetor / Float height adjustment / Carburetor fuel level adjustment / Carburetor rejetting / Fuel tank / Fuel valve / Throttle cable replacement / Air box

CHAPTER NINE / IGNITION SYSTEM
Component testing / Capacitor discharge ignition / Flywheel / Stator coils / Igniter / Ignition coil / Engine stop switch / Ignition timing / Powerjet assembly (1998)

CHAPTER TEN / LIQUID COOLING SYSTEM
Safety precautions / Cooling system check / Radiators / Water pump / Hoses

CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Front wheel / Rear wheel / Front and rear hubs / Rim and spoke service / Tire changing / Drive chain / Sprocket replacement

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Steering head / Front fork / Front fork service / Front fork adjustment

CHAPTER THIRTEEN / REAR SUSPENSION
Uni-trak rear suspension system / Shock absorber / Shock linkage / Rear swing arm / Rear suspension adjustment

CHAPTER FOURTEEN / BRAKES
Brake fluid selection / Disc brake / Front brake pads / Brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Brake hose replacement / Brake disc / Draining brake fluid / Brake bleeding / Rear brake pedal

CHAPTER FIFTEEN / BODY
Seat / Side covers / Radiator covers / Subframe

SUPPLEMENT / 1999-2000 SERVICE INFORMATION
Kips valve / Shift drum cam / Carburetor / Throttle position sensor / Capacitor / Rear suspension adjustment / Front master cylinder (2000 models)

INDEX

WIRING DIAGRAMS