Kawasaki KSF250 Mojave Repair Manual 1987-2004

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Item # M385-2  ISBN: 9781599691152




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This repair & service manual covers Kawasaki KSF250 Mojave 1987 to 2004 ATV models. The Mojave engine is a liquid-cooled, dual overhead camshaft, four-valve single cylinder. The valves are operated by two camshafts driven by a single cam chain.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual Organization | Notes, cautions and warnings | Safety first | Service hints | Washing the vehicle | Special tips | Torque specifications | Fasteners | Lubricants | RTV gasket sealant | Gasket remover | Threadlocking compound | Expendable supplies | Serial numbers | Warning and information labels | Basic hand tools | Precision measuring tools | Special tools | Fabricating tools | Mechanic's tips | Bearing replacement | Seals | Riding safety

CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Troubleshooting instruments | Starting the engine | Starting difficulties | Engine starting troubles | Engine is difficult to start | Poor idle speed performance | Poor running or high speed performance | Engine | Engine noises | Engine leak down test | Fuel system | Electrical troubleshooting | Ignition system | Clutch | Transmission and external shift mechanism | Drive train noise | Handling | Frame noise | Brakes

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Pre-ride checklist | Service intervals | Tires and wheels | Lubricants | Cleaning solvent | Periodic lubrication | Unscheduled lubrication | Periodic maintenance | Unscheduled maintenance | Engine tune-up | Storage

CHAPTER FOUR: ENGINE TOP END
Engine principles | Cylinder head cover | Cam chain tensioner | Camshaft | Cylinder head oil pipe | Rocker arms | Cam chain | Chain guides | Cylinder head | Valves and valve components | Cylinder | Piston and piston rings

CHAPTER FIVE: ENGINE LOWER END
Servicing engine in frame | Engine removal | Engine installation | Oil screen | Oil pump | Oil pipe | Magneto cover | Stator and pickup coils | Magneto rotor | Right balancer | Left balancer | Balancer drive gear | Primary gear and oil pump spur gear | Kickstarter | Kickstarter idler and reverse idler gears | Crankcase and crankshaft | Engine break-in

CHAPTER SIX: CLUTCH
Clutch cable | Clutch cover | Oil pressure relief valve | Clutch Release Mechanism | Clutch

CHAPTER SEVEN: TRANSMISSION and GEARSHIFT MECHANISM
External shift mechanism | Reverse mechanism cover | Reverse mechanism | Reverse cable | Transmission troubleshooting | Transmission | internal shift mechanism overhaul | Reverse shaft | Transmission inspection | Internal shift mechanism

CHAPTER EIGHT: FUEL and EXHAUST SYSTEMS
Carburetor operation | Carburetor | Carburetor adjustments | Throttle cable replacement | Throttle case | Choke cable replacement | Fuel tank | Fuel valve | Air filter housing | Surge tank | Exhaust system

CHAPTER NINE: ELECTRICAL SYSTEM
Magneto | | Ignition system | Ignition coil | Cooling fan system | Lighting system | Switches | Wiring and connectors | Wiring diagrams

CHAPTER TEN: COOLING SYSTEM
Hoses and hose clamps | Cooling system inspection | Coolant reservoir | Radiator and cooling fan | Cooling fan | Thermostat | Water pump

CHAPTER ELEVEN: FRONT SUSPENSION and STEERING
Wheel alignment | Front wheel | Front hub | Handlebar | Steering shaft | Tie rod | Steering knuckle | Control arms | Steering stopper adjustment | Shock absorber | Tires and wheels

CHAPTER TWELVE: REAR AXLE, SUSPENSION and FINAL DRIVE
Rear wheel | Rear hub | Drive chain (1987 models) | | Drive chain (1988-on) | Engine sprocket | Rear sprocket | Rear axle | Bearing housing | Swing arm | Shock absorber

CHAPTER THIRTEEN: BRAKES
Disc brake | Front brake pads | Front caliper | Front master cylinder | Front brake disc | Rear brake pads | Rear brake caliper | Rear caliper | Parking brake assembly | Rear master cylinder | Brake pedal | Rear brake disc | Brake hose replacement | Parking brake cable replacement | Parking brake lever | Brake bleeding

CHAPTER FOURTEEN: FRAME
Footpeg (1987-1988) | Footpeg (1989-on) | Front fender cover | Front fender | Front mud guard | Rear fender | Seat

INDEX

WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Kawasaki KSF250 Mojave Repair Manual 1987-2004