Used 1999-2005 Kawasaki KLX250 Service Manual Supplement

Description

This Used 1999-2005 Kawasaki KLX250 Service Manual Supplement provides service and repair information for Kawasaki KLX250 1999-2005 motorcycles. NOTE: This manual is a supplement to the base manual for KLX motorcycles. You will need to order the KLX250 base manual and this supplement in order to properly service your machine. Part# 99924-1165-03.

This manual covers:

1999 Kawasaki KLX250 motorcycles
2001 Kawasaki KLX250 motorcycles
2002 Kawasaki KLX250 motorcycles
2003 Kawasaki KLX250 motorcycles
2004 Kawasaki KLX250 motorcycles
2005 Kawasaki KLX250 motorcycles

1999-2005 Kawasaki KLX250 Service Manual Supplement  Table of Contents

General Information
Fuel System
Cooling System
Engine Top End
Engine Right Side/Left Side
Engine Lubrication System
Engine Removal/Installation
Crankshaft/Transmissio
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Frame
Electrical System
Appendix

1999-2005 Kawasaki KLX250 Service Manual Supplement Index of Topics

Chapter 1: General Information

Before Servicing
Model Identification
General Specifications
Periodic Maintenance Chart
Torque and Locking Agent
Technical Information – Digital Meter
Cable, Wire, and Hose Routing

Chapter 2: Fuel System

Exploded View
Exploded View (United Stated and Canada)
Specifications
Throttle Grip and Cables
Throttle Grip Free Play Inspection
Throttle Cable Lubrication and Inspection
Carburetor
Carburetor Disassembly Note (KLX250H6F)
Carburetor Assembly Note (KLX250H6F)
Fuel Tank
Fuel Tank Inspection (On and after KLX250-H4/J4)

Chapter 3: Cooling System

Exploded View
Coolant Flow Chart
Specifications

Chapter 4: Engine Top End

Exploded View
Clean Air System (KLX250H6F United States and Canada)
Air Suction Valve Inspection
Vacuum Switch Valve Removal
Vacuum Switch Valve Installation
Vacuum Switch Valve Test
Clean Air System Hose Inspection

Chapter 5: Engine Right Side/Left Side

Exploded View
Specifications
Clutch Lever and Cable
Clutch Lever Free Play Inspection
Clutch Lever Free Play Adjustment
Clutch Cable Lubrication
Clutch
Clutch Plate Assembly Inspection
Clutch Plate Assembly Adjustment
Clutch Plate, Wear, Damage Inspection
Clutch Plate Warp Inspection
Clutch Spring Free Length Measurement
Shift Lever Installation Note

Chapter  6: Engine Lubrication System

Exploded View
Specification
Engine Oil and Filter
Engine Oil Change (On and after KLX250-H3/J4)

Chapter 7: Engine Removal/Installation

Exploded View

Chapter 8: Crankshaft/Transmission

Exploded View

Chapter 9: Wheels/Tires

Exploded View
Specifications
Wheels (Rims)
Front Wheel Installation
Rear Wheel Installation

Chapter 10: Final Drive

Exploded View
Specifications
Sprocket
Engine Sprocket Removal (KLX250-H5 ~ H7, H6F)
Engine Sprocket Installation (KLX250-H5 ~ H7, H6F)

Chapter 11: Brakes

Exploded View
Specifications

Chapter 12: Suspension

Exploded View
Specifications

Chapter 13: Steering

Exploded View

Chapter 14: Frame

Exploded View

Chapter 15:

Electrical System
Exploded View
Specifications
Charging System
Alternator Cover Removal
Alternator Cover Installation
Alternator Stator Removal
Alternator Stator Installation
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Inspection
Stator Coil Inspection
Regulator Inspection
Ignition System
Crankshaft Sensor Inspection
Ignition Coil Inspection
Igniter Inspection
Electrical Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Carbon Brush Inspection
Commutator Inspection, Cleaning
Armature Inspection
Brush Lead Inspection
Terminal Bolt Inspection
Starter Relay Inspection
Starter Circuit Relay Inspection
Starter Motor Clutch
Starter Motor Clutch Removal
Starter Motor Clutch Installation Starter Motor Clutch Inspection
Torque Limiter Inspection
Digital Meter
Digital Meter Removal
Bulb Replacement
Switch Inspection
LCD Segment Inspection
Speedometer Inspection
Speed Sensor Power Inspection Speedometer Pulse Inspection
ODO Meter Inspection
TRIP A/B Meter Check
Lighting System
Turn Signal Relay Inspection
Switches and Sensor
Throttle Sensor Removal and Installation
Throttle Sensor Inspection
Throttle Sensor Position Adjustment
KLX250H6F Wiring Diagram (United States and Canada)
KLX250-H Wiring Diagram (Australia)
KLX250-J Wiring Diagram (Europe)

Chapter 16: Appendix

Troubleshooting