Kawasaki Ninja 250R Motorcycle. Service Manual (2007)

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-

sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of

the United States Environmental Protection Agency and California Air Resources Board. Addi-

tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance

with applicable regulations of the California Air Resources Board on vehicles sold in California

only.

1. Crankcase Emission Control System

This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors

are routed through an oil separator to the inlet side of the engine. While the engine is operating,

the vapors are drawn into combustion chamber, where they are burned along with the fuel and air

supplied by the fuel injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust

of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully

designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California in-

cludes a catalytic converter system.

3. Evaporative Emission Control System

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-

stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when

the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is

commonly referred to as the Act’s “tampering provisions”.

“Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this

title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer

knowingly to remove or render inoperative any such device or element of design after such

sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading

motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-

ingly to remove or render inoperative any device or element of design installed on or in a

motor vehicle or motor vehicle engine in compliance with regulations under this title follow-

ing its sale and delivery to the ultimate purchaser...”

NOTE

○The phrase “remove or render inoperative any device or element of design” has been generally

interpreted as follows.

1. Tampering does not include the temporary removal or rendering inoperative of de-

vices or elements of design in order to perform maintenance.

2. Tampering could include.

a.Maladjustment of vehicle components such that the emission standards are ex-

ceeded.

b.Use of replacement parts or accessories which adversely affect the performance

or durability of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the stan-

dards.

d.Permanently removing, disconnecting, or rendering inoperative any component or

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,

THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10

000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering

inoperative by any person other than for purposes of maintenance, repair, or replacement, of any

device or element of design incorporated into any new vehicle for the purpose of noise control

prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the

vehicle after such device or element of design has been removed or rendered inoperative by

any person.

Among those acts presumed to constitute tampering are the acts listed below.

• Replacement of the original exhaust system or muffler with a component not in compliance

with Federal regulations.

• Removal of the muffler(s) or any internal portion of the muffler(s).

• Removal of the air box or air box cover.

• Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such

modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by

The Quick Reference Guide shows you all

trained mechanics in a properly equipped shop.

of the product’s system and assists in locating

However, it contains enough detail and basic in-

their chapters. Each chapter in turn has its own

formation to make it useful to the owner who de-

comprehensive Table of Contents.

sires to perform his own basic maintenance and

For example, if you want ignition coil informa-

repair work. A basic knowledge of mechanics,

tion, use the Quick Reference Guide to locate

the proper use of tools, and workshop proce-

the Electrical System chapter. Then, use the

dures must be understood in order to carry out

Table of Contents on the first page of the chap-

maintenance and repair satisfactorily. When-

ter to find the ignition coil section.

ever the owner has insufficient experience or

Whenever you see symbols, heed their in-

doubts his ability to do the work, all adjust-

structions! Always follow safe operating and

ments, maintenance, and repair should be car-

maintenance practices.

ried out only by qualified mechanics.

DANGER

In order to perform the work efficiently and

DANGER indicates a hazardous situa-

to avoid costly mistakes, read the text, thor-

tion which, if not avoided, will result in

oughly familiarize yourself with the procedures

death or serious injury.

before starting work, and then do the work care-

fully in a clean area. Whenever special tools or

WARNING

equipment are specified, do not use makeshift

tools or equipment. Precision measurements

WARNING indicates a hazardous situa-

can only be made if the proper instruments are

tion which, if not avoided, could result

used, and the use of substitute tools may ad-

in death or serious injury.

versely affect safe operation.

For the duration of the warranty period,

NOTICE

we recommend that all repairs and scheduled

NOTICE is used to address practices not

maintenance be performed in accordance with

related to personal injury.

this service manual. Any owner maintenance or

repair procedure not performed in accordance

This manual contains four more symbols

with this manual may void the warranty.

which will help you distinguish different types

To get the longest life out of your vehicle:

of information.

• Follow the Periodic Maintenance Chart in the

Service Manual.

NOTE

○This note symbol indicates points of par-

• Be alert for problems and non-scheduled

maintenance.

ticular interest for more efficient and con-

venient operation.

• Use proper tools and genuine Kawasaki Mo-

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

• Indicates a procedural step or work to be

done.

Kawasaki motorcycles are introduced by the

○Indicates a procedural sub-step or how to do

Service Manual. Genuine parts provided as

the work of the procedural step it follows. It

spare parts are listed in the Parts Catalog.

also precedes the text of a NOTE.

• Follow the procedures in this manual care-

Indicates a conditional step or what action to

fully. Don’t take shortcuts.

take based on the results of the test or inspec-

• Remember to keep complete records of main-

tion in the procedural step or sub-step it fol-

tenance and repair with dates and any new

lows.

parts installed.

In most chapters an exploded view illustration

of the system components follows the Table of

How to Use This Manual

Contents. In these illustrations you will find the

In this manual, the product is divided into its

instructions indicating which parts require spec-

major systems and these systems make up the

ified tightening torque, oil, grease or a locking

manual’s chapters.

agent during assembly.

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera-

tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-

tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever

necessary. This section explains the items that require particular attention during the removal and

reinstallation or disassembly and reassembly of general parts.

Especially note the following.

Battery Ground

Before completing any service on the motorcycle, discon-

nect the battery cables from the battery to prevent the en-

gine from accidentally turning over. Disconnect the ground

cable (-) first and then the positive (+). When completed

with the service, first connect the positive (+) cable to the

positive (+) terminal of the battery then the negative (-) ca-

ble to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury

from possible sharp edges on the parts.

Solvent

Use a high-flush point solvent when cleaning parts. High

-flush point solvent should be used according to directions

of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or

other foreign materials entering into sealed areas during ve-

hicle disassembly can cause excessive wear and decrease

performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the

parts according to the order the parts were disassembled

and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been

cleaned, store the parts in a clean area. Put a clean cloth

or plastic sheet over the parts to protect from any foreign

materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious ac-

cident. Visually inspect removed parts for corrosion, discol-

oration, or other damage. Refer to the appropriate sections

of this manual for service limits on individual parts. Replace

the parts if any damage has been found or if the part is be-

yond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or

recommended by KAWASAKI. Gaskets, O-rings, oil seals,

grease seals, circlips, cotter pins or self-looking nuts must

be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassem-

bly, however, if assembly order is provided in this Service

Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts,

or screws, start them all in their holes and tighten them to

a snug fit. Then tighten them according to the specified se-

quence to prevent case warpage or deformation which can

lead to malfunction. Conversely when loosening the bolts,

nuts, or screws, first loosen all of them by about a quar-

ter turn and then remove them. If the specified tightening

sequence is not indicated, tighten the fasteners alternating

diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may

lead to serious damage. Tighten fasteners to the specified

torque using a good quality torque wrench.

Force

Use common sense during disassembly and assembly,

excessive force can cause expensive or hard to repair dam-

age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and

O-rings after disassembly can reduce sealing performance.

Remove the old gaskets and clean the sealing surfaces

thoroughly so that no gasket material or other material re-

mains. Install the new gaskets and replace the used O-rings

when re-assembling

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a

Non-permanent Locking Agent, clean the surfaces so

that no oil residue remains before applying liquid gasket or

non-permanent locking agent. Do not apply them exces-

sively. Excessive application can clog oil passages and

cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be

pressed into place, apply small amount of oil to the con-

tact area. Be sure to maintain proper alignment and use

smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is

absolutely necessary. Replace with new ones whenever

removed. Press bearings with the manufacturer and size

marks facing out. Press the bearing into place by putting

pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between

the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal

is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing

out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing

the seal.

Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with

new ones. Take care not to open the clip excessively when

installing to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during

assembly to minimize wear during initial operation. Lubri-

cation points are called out throughout this manual, apply

the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play

amount of rotating direction will affect the adjustment. Ro-

tate the crankshaft to positive direction (clockwise viewed

from output side).

Electrical Wires

A two-color wire is identified first by the primary color and

then the stripe color. Unless instructed otherwise, electrical

wires must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate

measurement. Read the manufacture’s instructions thor-

oughly before using the meter. Incorrect values may lead

to improper adjustments.

1-8 GENERAL INFORMATION

General Specifications

Items

EX250J8 ∼ JC

Dimensions

Overall Length

2 085 mm (82.1 in.), (AU) 2 080 mm (81.9 in.)

Overall Width

715 mm (28.1 in.)

Overall Height

1 110 mm (43.7 in.), (AU) 1 115 mm (43.9 in.)

Wheelbase

1 400 mm (55.1 in.), (AU) 1 390 mm (54.7 in.)

Road Clearance

130 mm (5.1 in.), (AU, ID) 140 mm (5.5 in.)

Seat Height

775 mm (30.5 in.)

Dry Mass

EX250J8

152 kg (335 lb), (CAL) 153 kg (337 lb), (IN) 154 kg (340 lb)

Curb Mass:

EX250J9 ∼ JC

170 kg (375 lb), (AU) 169 kg (373 lb)

Front

82 kg (181 lb), (ID) 83 kg (183 lb)

Rear

88 kg (194 lb), (AU, ID) 87 kg (192 lb)

Fuel Tank Capacity

18 L (4.8 US gal.)

Performance

Minimum Turning Radius

2.7 m (8.9 ft)

Engine

Type

4-stroke, DOHC, 2-cylinder

Cooling System

Liquid-cooled

Bore and Stroke

62.0 × 41.2 mm (2.5 × 1.6 in.)

Displacement

249 cm³ (15.2 cu in.)

Compression Ratio

11.6

Maximum Horsepower

24 kW (32.6 PS) @11 000 r/min (rpm)

(ID) 23.4 kW (31.8 PS) @11 000 r/min (rpm)

Maximum Torque

22.0 N·m (2.24 kgf·m, 16.2 ft·lb) @9 500 r/min (rpm)

Carburetion System

Carburetor, Keihin CVK 30× 2

Starting System

Electric starter

Ignition System

Battery and coil (transistorized)

Timing Advance

Electronically advanced

Ignition Timing

From 10° BTDC @1 300 r/min (rpm) to

35° BTDC @4 000 r/min (rpm)

Spark Plug

NGK CR8E or ND U24ESR-N

Cylinder Numbering Method

Left to right, 1-2

Firing Order

1-2

Valve Timing:

Inlet:

Open

36° BTDC

56° ABDC

Duration

272°

Exhaust:

Open

61° BBDC

31° ATDC

Duration

272°

GENERAL INFORMATION 1-9

General Specifications

Items

EX250J8 ∼ JC

Lubrication System

Forced lubrication (wet sump)

Engine Oil:

Type

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity

SAE10W-40

Capacity

1.7 L (1.80 US qt)

Drive Train

Primary Reduction System:

Type

Gear

Reduction Ratio

3.087 (71/23)

Clutch Type

Wet multi disc

Transmission:

Type

6-speed, constant mesh, return shift

Gear Ratios:

1st

2.600 (39/15)

2nd

1.789 (34/19)

3rd

1.409 (31/22)

4th

1.160 (29/25)

5th

1.000 (27/27)

6th

0.893 (25/28)

Final Drive System:

Type

Chain drive

Reduction Ratio

3.214 (45/14), (AU) 3.071 (43/14)

Overall Drive Ratio

8.859 @Top gear, (AU) 8.466 @Top gear

Frame

Type

Tubular, diamond

Caster (Rake Angle)

26°

Trail

82 mm (3.2 in.)

Front Wheel:

Tire Type

Tubeless

Tire Size:

EX250J8

110/70-17M/C 54H

EX250J9 ∼ JC

110/70-17M/C 54S

Rim Size

17 M/C × MT2.75

Rear Wheel:

Tire Type

Tubeless

Tire Size:

EX250J8

130/70-17M/C 62H

EX250J9 ∼ JC

130/70-17M/C 62S

Rim Size

17 M/C × MT3.50

Front Suspension:

Type

Telescopic fork

Wheel Travel

120 mm (4.7 in.)

GENERAL INFORMATION 1-11

Unit Conversion Table

Prefixes for Units:

Units of Length:

Prefix

Symbol

Power

0.6214

mile

mega

1 000 000

3.281

kilo

1 000

0.03937

centi

0.01

milli

0.001

micro

0.000001

Units of Torque:

N·m

0.1020

kgf·m

N·m

0.7376

ft·lb

Units of Mass:

N·m

8.851

in·lb

2.205

kgf·m

9.807

N·m

0.03527

kgf·m

7.233

ft·lb

kgf·m

86.80

in·lb

Units of Volume:

0.2642

gal (US)

Units of Pressure:

0.2200

gal (IMP)

kPa

0.01020

kgf/cm²

1.057

qt (US)

kPa

0.1450

psi

0.8799

qt (IMP)

kPa

0.7501

cm Hg

2.113

pint (US)

kgf/cm²

98.07

kPa

1.816

pint (IMP)

kgf/cm²

14.22

psi

0.03381

oz (US)

cm Hg

1.333

kPa

0.02816

oz (IMP)

0.06102

cu in

Units of Speed:

km/h

0.6214

mph

Units of Force:

0.1020

0.2248

Units of Power:

9.807

1.360

2.205

1.341

0.7355

0.9863

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart

2-3

Torque and Locking Agent

2-7

Specifications

2-12

Special Tools

2-14

Periodic Maintenance Procedures

2-15

Fuel System

2-15

Air Cleaner Element Cleaning

2-15

Air Cleaner Element Installation

2-16

Throttle Control System Inspection

2-16

Choke Operation Inspection

2-18

Engine Vacuum Synchronization Inspection

2-18

Idle Speed Inspection

2-19

Idle Speed Adjustment

2-19

Fuel Hose Inspection (fuel leak, damage, installation condition)

2-20

Evaporative Emission Control System (CAL Model)

2-20

Evaporative Emission Control System Inspection

2-20

Cooling System

2-21

Coolant Level Inspection

2-21

Radiator Hose Damage and Installation Condition Inspection

2-22

Coolant Filter Cleaning (Australia Model)

2-22

Air Suction System

2-22

Air Suction System Damage Inspection

2-22

Engine Top End

2-23

Valve Clearance Inspection

2-23

Valve Clearance Adjustment

2-24

Clutch

2-26

Clutch Operation Inspection

2-26

Wheels/Tires

2-27

Air Pressure Inspection

2-27

Wheel/Tire Damage Inspection

2-27

Tire Tread Wear, Abnormal Wear Inspection

2-27

Wheel Bearing Damage Inspection

2-28

Drive Train

2-29

Drive Chain Lubrication Condition Inspection

2-29

Drive Chain Slack Inspection

2-29

Drive Chain Slack Adjustment

2-30

Wheel Alignment Inspection

2-31

Drive Chain Wear Inspection

2-31

Chain Guide Inspection

2-32

Brake System

2-32

Brake Fluid Leak (Brake Hose and Pipe) Inspection

2-32

Brake Hose and Pipe Damage and Installation Condition Inspection

2-32

Brake Operation Inspection

2-33

Brake Fluid Level Inspection

2-33

Brake Pad Wear Inspection

2-34

Brake Light Switch Operation Inspection

2-34

Suspensions

2-35

Front Forks/Rear Shock Absorber Operation Inspection

2-35

Front Fork Oil Leak Inspection

2-35

Rear Shock Absorber Oil Leak Inspection

2-35

2-2 PERIODIC MAINTENANCE

Rocker Arm Operation Inspection

2-35

Tie-Rod Operation Inspection

2-36

Swingarm Pivot Lubrication

2-36

Steering System

2-36

Steering Play Inspection

2-36

Steering Play Adjustment

2-37

Steering Stem Bearing Lubrication

2-37

Electrical System

2-38

Lights and Switches Operation Inspection

2-38

Headlight Aiming Inspection

2-40

Sidestand Switch Operation Inspection

2-41

Engine Stop Switch Operation Inspection

2-42

Others

2-43

Chassis Parts Lubrication

2-43

Bolts, Nuts and Fasteners Tightness Inspection

2-44

Replacement Parts

2-45

Air Cleaner Element Replacement

2-45

Fuel Hose Replacement

2-45

Coolant Change

2-45

Radiator Hose and O-ring Replacement

2-47

Engine Oil Change

2-48

Oil Filter Replacement

2-48

Brake Hose and Pipe Replacement

2-49

Brake Fluid Change

2-49

Master Cylinder Rubber Parts Replacement

2-51

Caliper Rubber Parts Replacement

2-52

Spark Plug Replacement

2-53

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in

good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

first

(× 1 000 mile)

See

Page

INSPECTION

Every

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Fuel System

Air cleaner element - clean

2-15

•

Throttle control system (play,

year

2-16

smooth return, no drag) - inspect

•

Choke operation - inspect

year

2-18

•

Engine vacuum synchronization

2-18

- inspect

•

Idle speed - inspect

2-19

•

Fuel leak (fuel hose and pipe) -

year

2-20

inspect

•

Fuel hose and pipe damage -

year

2-20

inspect

•

Fuel hose and pipe installation

year

2-20

condition - inspect

•

Evaporative emission control

2-20

system function (CAL) - inspect

•

Cooling System

Coolant level - inspect

2-21

•

Coolant leak (water hose and

year

2-22

pipe) - inspect

•

Water hose damage - inspect

year

2-22

•

Water hose installation condition

year

2-22

- inspect

•

Coolant filter - clean

year

2-22

Air Suction System

Air suction system damage -

2-22

inspect

•

Engine Top End

Valve clearance - inspect

2-23

•

Clutch

Clutch operation (play,

disengagement, engagement) -

2-26

•

inspect

Wheels and Tires

Tire air pressure - inspect

year

2-27

•

Wheel/tire damage - inspect

2-27

•

Tire tread wear, abnormal wear

2-27

- inspect

•

Wheel bearing damage - inspect

year

2-28

•

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

first

(× 1 000 mile)

See

Page

INSPECTION

Every

(0.6)

(3.75)

(7.5)

(11.25)

(15)

(18.75)

(22.5)

Drive Train

Drive chain lubrication condition

Every 600 km (375 mile)

2-29

- inspect #

Drive chain slack - inspect #

Every 1

000 km (600

mile)

2-29

Drive chain wear - inspect #

2-31

•

Drive chain guide wear - inspect

2-32

•

Brakes

Brake fluid leak (brake hose and

year

2-32

pipe) - inspect

•

Brake hose and pipe damage -

year

2-32

inspect

•

Brake hose and pipe installation

year

2-32

condition - inspect

•

Brake operation (effectiveness,

year

2-33

play, no drag) - inspect

•

Brake fluid level - inspect

6 months

2-33

•

Brake pad wear - inspect #

2-34

•

Brake light switch operation -

2-34

inspect

•

Suspension

Front forks/rear shock absorber

operation (damping and smooth

2-35

•

stroke) - inspect

Front forks/rear shock absorber

year

2-35

oil leak - inspect

•

Rocker arm operation - inspect

2-35

•

Tie-rods operation - inspect

2-36

•

Swingarm pivot - lubricate

2-36

•

Steering

Steering play - inspect

year

2-36

•

Steering stem bearings -

2 years

2-37

lubricate

•

Electrical System

Lights and switches operation -

year

2-38

inspect

•

Headlight aiming - inspect

year

2-40

•

Sidestand switch operation -

year

2-41

inspect

•

Engine stop switch operation -

year

2-42

inspect

•

2-6 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY

Whichever

* ODOMETER READING

comes

× 1 000 km

first

(× 1 000

mile)

See

Page

CHANGE/REPLACE ITEM

Every

(0.6)

(7.5)

(15)

(22.5)

(30)

Air cleaner element # - replace

2 years

2-44

Fuel hose - replace

5 years

2-44

Coolant - change

3 years

2-44

•

Radiator hose and O-ring - replace

3 years

2-46

•

Engine oil # - change

year

2-47

•

Oil filter - replace

year

2-47

•

Brake hose and pipe - replace

4 years

2-48

•

Brake fluid - change

2 years

2-48

•

Rubber parts of master cylinder and caliper -

4 years

2-50

replace

•

Spark plug - replace

2-52

•

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or

frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Use a torque wrench to tighten bolts and nuts to their specified torque values. If too little torque is

applied, the bolts and nuts could loosen and fall out. If too much torque is applied, the threads could

be sheared off.

To tighten a bolt or a nut, or to check their torque, loosen the bolt or nut one-half turn before tight-

ening it to the specified torque.

Letters used in the “Remarks” column mean:

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent to the threads.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

R: Replacement Parts

S: Tighten the fasteners following the specified sequence.

Si: Apply silicone grease.

SS: Apply silicone sealant.

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Fuel System

Fuel Tap Mounting Bolts

2.5

0.25

22 in·lb

Fuel Gauge Mounting Bolts

6.9

0.7

61 in·lb

Air Cleaner Housing Cap Bolts/Screws

2.5

0.25

22 in·lb

Air Cleaner Housing Screws

1.15

0.12

10 in·lb

Air Cleaner Housing Mounting Bolts

9.8

1.0

87 in·lb

Air Cleaner Housing Clamp Screws

2.0

0.2

18 in·lb

Separate Bracket Bolt

9.8

1.0

87 in·lb

Cooling System

Water Temperature Switch

7.5

0.76

66 in·lb

Thermostat Cover Bolts

9.8

1.0

87 in·lb

Thermostat Housing Mounting Bolts

9.8

1.0

87 in·lb

Radiator Fan Switch

23.5

2.4

Radiator Bolts

9.8

1.0

87 in·lb

Radiator Cap Bracket Bolt

9.8

1.0

87 in·lb

Water Pipe Bolts

9.8

1.0

87 in·lb

Water Hose Clamp Screws

3.0

0.31

27 in·lb

Drain Bolt

9.8

1.0

87 in·lb

Water Pump Cover Bolts

9.8

1.0

87 in·lb

Water Pump Bolts

9.8

1.0

87 in·lb

Reserve Tank Cap

Hand-Tighten

Reserve Tank Bolts

9.8

1.0

87 in·lb

Reserve Tank Bracket Bolt

9.8

1.0

87 in·lb

Engine Top End

Cylinder Head Cover Bolts

9.8

1.0

87 in·lb

Camshaft Sprocket Bolts

1.5

Chain Tensioner Cap Bolt

5.0

0.5

44 in·lb

Air Suction Cover Bolts

9.8

1.0

87 in·lb

Vacuum Switch Valve Bracket Bolts

9.8

1.0

87 in·lb

Rear Camshaft Chain Guide Bolt-Lower

1.7

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Chain Tensioner Mounting Bolts

9.8

1.0

87 in·lb

Camshaft Cap Bolts

1.2

106 in·lb

Cylinder Head Bolt (M6)

1.2

106 in·lb

MO, S

Cylinder Head Bolts (M8)

31.4

3.2

MO, S

Water Passage Plugs

2.0

Carburetor Holder Clamp Screws

2.0

0.2

18 in·lb

Water Drain Bolt

5.9

0.6

52 in·lb

Muffler Body Rear Cover Bolts

9.8

1.0

87 in·lb

Muffler Body Mounting Bolt

3.1

Muffler Body Clamp Bolt

1.7

Muffler Cover Bolts

9.8

1.0

87 in·lb

Muffler Cover Clamp Screw

6.9

0.70

61 in·lb

Exhaust Pipe Mounting Bolt

9.8

1.0

87 in·lb

Exhaust Pipe Holder Nuts

1.2

104 in·lb

Clutch

Clutch Lever Holder Clamp Bolts

8.8

0.9

78 in·lb

Clutch Spring Bolts

8.8

0.9

78 in·lb

Clutch Hub Nut

132

13.5

97.4

Oil Filler Plug

Hand-Tighten

Clutch Cover Bolts

9.8

1.0

87 in·lb

Engine Lubrication System

Oil Hose Banjo Bolts

19.6

2.0

14.5

Oil Pressure Relief Valve

1.5

Crankcase Oil Passage Plug

1.5

Oil Passage Plugs for Oil Pump

2.0

Oil Pipe Banjo Bolts

1.2

104 in·lb

Oil Drain Bolt

19.6

2.0

14.5

Oil Pressure Switch

1.5

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

Oil Filter Mounting Bolts

19.6

2.0

14.5

Oil Breather Mounting Bolts

9.8

1.0

87 in·lb

Oil Pump Mounting Bolts

9.8

1.0

87 in·lb

Oil Screen Cover Bolts

9.8

1.0

87 in·lb

Plug

19.6

2.0

14.5

Breather Bolt

9.8

1.0

87 in·lb

Engine Removal/Installation

Engine Mounting Bracket Bolts and Nuts

6.5

Engine Mounting Nuts

6.5

Crankshaft/Transmission

Oil Breather Mounting Bolts

9.8

1.0

87 in·lb

Crankcase Bolts

1.2

104 in·lb

Crankcase Bolts

8 (L = 90)

2.4

MO, S

Crankcase Bolts

8 (L = 73)

1.9

MO, S

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Starter Motor Clutch Bolts

34.3

3.5

Connecting Rod Big End Cap Nuts

27.5

2.8

Shift Drum Bearing Holder Bolt

1.2

104 in·lb

Shift Drum Pin Plate Bolt

9.0

0.9

80 in·lb

Neutral Switch

1.5

External Shift Mechanism Return Spring Pin

19.6

2.0

14.5

Shift Drum Positioning Bolt

24.5

2.5

Shift Lever Link Bolt

1.2

104 in·lb

Front Tie-Rod Locknut (Left-Hand Threads)

7.0

0.7

62 in·lb

Rear Tie-Rod Locknut (Right-Hand Threads)

7.0

0.7

62 in·lb

EX250J8 ∼ JB (with a non-permanent locking

agent)

Shift Pedal Mounting Bolt

2.0

EX250JB ∼ JC (with a non-permanent locking

agent)

Shift Pedal Mounting Bolt

2.5

Wheels/Tires

Front Axle Nut

9.0

Rear Axle Nut

10.0

Final Drive

Engine Sprocket Cover Bolts

9.8

1.0

87 in·lb

Engine Sprocket Nut

127

Rear Sprocket Nuts

6.0

Rear Sprocket Studs

Brakes

Brake Lever Pivot Bolt Locknut

5.9

0.6

52 in·lb

Bleed Valve

5.5

0.55

49 in·lb

Front Master Cylinder Clamp Bolts

8.8

0.9

78 in·lb

Brake Disc Mounting Bolts

2.8

Brake Hose Banjo Bolts

2.5

Front Caliper Mounting Bolts

2.5

Front Brake Light Switch Screw

1.0

0.1

9 in·lb

Brake Lever Pivot Bolt

1.0

0.1

9 in·lb

Front Reservoir Cap Screws

1.5

0.15

13 in·lb

Reservoir Mounting Bolt

6.9

0.7

61 in·lb

Bleed Valve

5.5

0.55

49 in·lb

Brake Pedal Pivot Bolt

8.8

0.9

78 in·lb

Push Rod Locknut

1.8

Brake Disc Mounting Bolts

2.8

Brake Hose Banjo Bolts

2.5

Rear Master Cylinder Mounting Bolts

2.5

Rear Caliper Mounting Bolts

2.5

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

Remarks

N·m

kgf·m

ft·lb

Suspension

Front Fork Clamp Bolts (Upper)

2.1

Front Fork Clamp Bolts (Lower)

3.1

Front Fork Bottom Allen Bolts

2.0

Rocker Arm Pivot Nut

6.0

Tie-Rod Nuts

6.0

Rear Shock Absorber Mounting Nuts

6.0

Swingarm Pivot Nut

10.0

Steering

Steering Stem Nut

4.9

0.5

43 in·lb

Handlebar Holder Mounting Bolts

2.5

Steering Stem Head Bolt

4.5

Front Fork Clamp Bolts (Upper)

2.0

Front Fork Clamp Bolts (Lower)

3.1

Frame

Sidestand Nut

4.0

Front Footpeg Bracket Mounting Bolts

2.5

Rear Footpeg Bracket Mounting Bolts

2.5

Sidestand Switch Bolt

8.8

0.90

78 in·lb

Windshield Mounting Screws

0.42

0.043

3.7 in·lb

Electrical System

Tail/Brake Light Mounting Bolts

5.9

0.6

52 in·lb

Plugs on Alternator Cover

Hand-Tighten

Alternator Cover Bolts

9.8

1.0

87 in·lb

Alternator Rotor Bolt

88.2

9.0

Alternator Stator Bolts

1.2

104 in·lb

Regulator/Rectifier Bolts

9.8

1.0

87 in·lb

Starter Motor Clutch Bolts

34.3

3.5

Crankshaft Sensor Screws

3.0

0.30

27 in·lb

Ignition Coil Bolts

see text

Spark Plugs

1.3

115 in·lb

Starter Motor Terminal Locknut

9.8

1.0

87 in·lb

Starter Motor Assembly Bolts

3.5

0.36

31 in·lb

Starter Motor Mounting Bolts

9.8

1.0

87 in·lb

Starter Relay Terminal Nut

5.0

0.5

44 in·lb

Oil Pressure Switch

1.5

Neutral Switch

1.5

PERIODIC MAINTENANCE 2-11

Torque and Locking Agent

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and

nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the

values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads

Torque

dia. (mm)

N·m

kgf·m

ft·lb

3.4 ∼ 4.9

0.35 ∼ 0.50

30 ∼ 43 in·lb

5.9 ∼ 7.8

0.60 ∼ 0.80

52 ∼ 69 in·lb

14 ∼19

1.4 ∼1.9

10.0 ∼ 13.5

25 ∼ 34

2.6 ∼ 3.5

19.0 ∼ 25

44 ∼ 61

4.5 ∼ 6.2

33 ∼ 45

73 ∼ 98

7.4 ∼ 10.0

54 ∼ 72

115 ∼ 155

11.5 ∼ 16.0

83 ∼ 115

165 ∼ 225

17.0 ∼ 23.0

125 ∼ 165

225 ∼ 325

23 ∼ 33

165 ∼ 240

2-12 PERIODIC MAINTENANCE

Specifications

Item

Standard

Service Limit

Fuel System

Throttle Grip Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

- - -

Idle Speed

1 300 ±50 r/min (rpm)

- - -

Carburetor Synchroniza-

Less than 2.7 kpa (2 cmHg) difference

- - -

tion Vacuum

between two carburetors

Air Cleaner Element

Polyurethane foam

- - -

Cooling System

Coolant:

Type (Recommended)

Permanent type antifreeze

- - -

Color

Green

- - -

Mixed Ratio

Soft water 50%, coolant 50%

- - -

Freezing Point

-35°C (-31°F)

- - -

Capacity

1.5 L (1.59 US qt)

- - -

Engine Top End

Valve Clearance:

Inlet

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

- - -

Exhaust

0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)

- - -

Clutch

Clutch Lever Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

- - -

Engine Lubrication System

Engine Oil:

Grade

API SG, SH, SJ, SL or SM with JASO MA,

- - -

MA1 or MA2

Viscosity

SAE 10W-40

- - -

Capacity

1.3 L (1.4 US qt) (when filter is not removed)

- - -

1.6 L (1.7 US qt) (when filter is removed)

Level

Between upper and lower level lines (Wait 2 ∼

- - -

3 minutes after idling or running)

Wheels/Tires

Tread Depth:

Front:

BRIDGESTONE

4.6 mm (0.181 in.)

1 mm (0.04 in.)

DUNLOP

4.5 mm (0.177 in.)

IRC

4.2 mm (0.165 in.)

Rear:

BRIDGESTONE

7.0 mm (0.276 in.)

2 mm (0.08 in.) up to

130 km/h (80 mph)

DUNLOP

7.4 mm (0.291 in.)

3 mm (0.12 in.) over

IRC

6.5 mm (0.256 in.)

130 km/h (80 mph)

Air pressure: (when Cold)

Front

Up to 170 kg (375 lb) load: 200 kPa (2.0

- - -

kgf/cm², 28 psi)

Rear

Up to 170 kg (375 lb) load: 225 kPa (2.25

- - -

kgf/cm², 32 psi)

Final Drive

Drive Chain Slack

20 ∼ 30 mm (0.8 ∼ 1.2 in.)

- - -

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

WARNING

Gasoline and low-flash point solvents can be

flammable and/or explosive and cause severe

burns. Clean the element in a well ventilated area,

and take care that there is no spark or flame any-

where near the working areas. Do not use gasoline

or low-flash point solvents to clean the element.

• Clean the element [A] in a bath of high-flash point solvent.

Squeeze it dry in a clean towel. Do not wring the element

or blow it dry; the element can be damaged.

• Check all the parts of the element for visible damage.

If any of the parts of the element are damaged, replace

them.

• After cleaning, saturate the element with a high-quality

foam-air-filter oil, squeeze out the excess, then wrap it in

a clean towel and squeeze it as dry as possible.

○Be careful not to tear the sponge filter.

Air Cleaner Element Installation

• Install the removed parts in reverse of removal.

• Torque the air cleaner cap bolts.

Torque - Air Cleaner Cap Bolts:

2.5 N·m (0.25 kgf·m, 22

in·lb)

Throttle Control System Inspection

• Check that the throttle grip moves smoothly from full open

to close [A], and the throttle closes quickly and completely

by the return spring in all steering positions.

If the throttle grip doesn’t return properly, check the throt-

tle cable routing, grip free play, and cable damage. Then

lubricate the throttle cable.

• Check the throttle grip free play [A].

If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free Play

Standard:

2∼3mm(0.08∼0.12in.)

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

• Loosen the locknut [A], and screw accelerator cable ad-

juster [B] in completely so as to give the throttle grip plenty

of play.

• Turn the accelerator cable adjuster until 2 ∼ 3 mm (0.08 ∼

0.12 in.) of throttle grip play is obtained.

• Tighten the locknut.

If the throttle cables can not be adjusted by using the ca-

ble adjuster at the upper end of the throttle cable, use the

cable adjusters at the lower ends of the throttle cables.

• Remove:

Side Cover (see Side Cover Removal in the Frame chap-

ter)

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

• To make service easy, unscrew the reserver tank bolts

and remove the reserver tank with hoses

• Turn out both upper nuts [A] and turn in both lower nuts [B]

as far as they will go so as to give the throttle grip plenty

of play.

• With the throttle grip completely closed, turn out the lower

nut and turn in the upper nut of the decelerator cable [C]

until the inner cable just becomes tight.

• Turn out the lower nut and turn in the upper nut of the

accelerator cable [D] until the correct free play is obtained.

• Check that the throttle linkage lever [A] stops against the

idle adjusting screw [B] with the throttle grip closed.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Choke Operation Inspection

• Remove:

Front Seat (see Front Seat Removal in the Frame chap-

ter)

Fuel Tank (see Fuel Tank Removal)

Side Covers (see Side Cover Removal in the Frame

chapter)

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Fuel Tank (see Fuel Tank Removal)

• Push the choke lever [A] back all the way to its released

position.

• Check choke cable free play [B].

○Determine the amount of choke cable play at the choke

lever.

If the free play is incorrect, adjust the choke cable.

Choke Cable Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

• Push the choke lever back all the way to its released po-

sition.

• Pull the choke lever until the starter plunger lever [A] at the

carburetor touches the starter plunger [B]; the amount of

choke lever travel is the amount of choke cable play.

• Loosen the locknut [A], and turn the adjuster [B] until the

cable has the proper amount of free play.

• Tighten the locknut securely.

Engine Vacuum Synchronization Inspection

• Situate the motorcycle using the center stand so that it is

perpendicular to the ground.

• Remove the fuel tank, and connect the sub-fuel tank to

supply the fuel.

• Remove the right lower fairing.

• Warm up the engine.

• Check the idle speed and adjust if necessary.

• Pull the vacuum hoses off, and attach vacuum gauge [A]

to the vacuum hose fittings on the carburetors.

Special Tool - Vacuum Gauge KEK-55-5: 57001-1369

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

• Start the engine and let it idle to measure the carburetor

intake vacuum.

If the intake vacuum difference between the two cylinders

exceeds the limit, adjust the synchronization.

Engine Vacuum Synchronization

Less than 2.7 kPa (2 cmHg) difference between both

cylinders

• Turn the adjusting screw [A] to synchronize the carbure-

tor.

If the carburetor synchronization cannot be obtained by

using the adjusting screw, check for dirt or blockage, and

then check the pilot screw settings.

• Check the Carburetor Synchronization again.

NOTE

○Do not turn the pilot screws carelessly during carburetor

synchronization. You may cause poor running at low

engine speed.

Idle Speed Inspection

• Start the engine and warm it up thoroughly.

• With the engine idling, turn the handlebar to both sides

[A].

If handlebar movement changes the idle speed, the

throttle cables may be improperly adjusted or incorrectly

routed or damaged. Be sure to correct any of these

conditions before riding (see Throttle Control System

Inspection or Cable, Wire, and Hose Routing section in

the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly

routed or damaged cables could result in an unsafe

riding Condition. Follow the service manual to be

make sure to correct any of these conditions.

• Check idle speed.

If the idle speed is out of the specified range, adjust it.

Idle Speed

Standard:

1 300 ±50 r/min (rpm)

Idle Speed Adjustment

• Start the engine and warm it up thoroughly.

• Turn the adjusting screw [A] until the idle speed is correct.

○Open and close the throttle a few times to make sure that

the idle speed is within the specified range. Readjust if

necessary.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel Hose Inspection (fuel leak, damage,

installation condition)

○The fuel hose is designed to be used throughout the mo-

torcycle’s life without any maintenance. However, if the

motorcycle is not properly handled, the high pressure in-

side the fuel line can cause fuel to leak [A] or the hose to

burst. Remove the fuel tank (see Fuel Tank Removal in

the Fuel System chapter) and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B], bulges [C]

or ozone cracks [D] are noticed.

• Check that the hose [A] are securely connected and

clamps [B] are tightened correctly.

• Check that the hoses are routed according to Cable, Wire,

and Hose Routing section in the Appendix chapter.

Replace the hose if it has been sharply bent or kinked.

Evaporative Emission Control System (CAL Model)

Evaporative Emission Control System Inspection

• Inspect the canister as follows.

○Remove:

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

○Remove the canister [A], and disconnect the hoses from

the canister.

○Visually inspect the canister for cracks or other damage.

If the canister has any cracks or bad damage, replace it

with a new one.

NOTE

○The canister is designed to work well through the motor-

cycle’s life without any maintenance if it is used under

normal conditions.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

• Check the liquid/vapor separator as follows.

○Remove:

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

○Disconnect the hoses from the separator, and remove the

separator [B] from the motorcycle left side.

○Visually inspect the separator for cracks and other dam-

age.

If the separator has any cracks or damage, replace it with

a new one.

○To prevent the gasoline from flowing into or out of the

canister, hold the separator perpendicular to the ground.

• Check the hoses of the evaporative emission control sys-

tem as follows.

○Check that the hoses are securely connected and clips

are in position.

○Replace any kinked, deteriorated or damaged hoses.

○Route the hoses according to Cable, Wire, and Hose

Routing section in the Appendix chapter.

○When installing the hoses, avoid sharp bending, kinking,

flattening or twisting, and route the hoses with a minimum

of bending so that the emission flow will not be obstructed.

Cooling System

Coolant Level Inspection

NOTE

○Check the level when the engine is cold (room or ambi-

ent temperature).

• Check the coolant level in the reserve tank [A] with the

motorcycle held perpendicular (Do not use the sidestand).

If the coolant level is lower than the “L” level line [B], re-

move the right center fairing (see Center Fairing Removal

in the Frame chapter) and unscrew the reserve tank cap,

and add coolant to the “F” level line [C].

“L”: low

“F”: full

NOTICE

For refilling, add the specified mixture of coolant

and soft water. Adding water alone dilutes the

coolant and degrades its anticorrosion properties.

The diluted coolant can attack the aluminum en-

gine parts. In an emergency, soft water alone can

be added. But the diluted coolant must be returned

to the correct mixture ratio within a few days.

If coolant must be added often or the reservoir tank

has run completely dry, there is probably leakage in

the cooling system. Check the system for leaks.

Coolant ruins painted surfaces. Immediately wash

away any coolant that spills on the frame, engine,

wheels or other painted parts.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Radiator Hose Damage and Installation Condition

Inspection

○The high pressure inside the radiator hose and pipe can

cause coolant to leak [A] or the hose to burst if the line is

not properly maintained.

• Visually inspect the hoses for signs of deterioration.

Squeeze the hoses. A hose should not be hard and

brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [B] or bulges [C]

are noticed.

• Check that the hoses are securely connected and clamps

are tightened correctly.

Torque - Radiator Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

Coolant Filter Cleaning (Australia Model)

• Remove the fuel tank (see Fuel Tank Removal in the Fuel

System chapter).

• Drain the coolant (see Coolant Change).

• Remove the filter [A] from the water hoses [B] of carbure-

tor system.

• Blow off dirt and sediment on the filter with compressed

air.

Filter Body [C]

Water Pipe [D]

Coolant Valve Assy [E]

Water Pump [F]

Carburetor [G]

Damper [H]

Air Suction System

Air Suction System Damage Inspection

• Pull the vacuum switch valve hose [A] out of the air

cleaner.

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

• Start the engine and run it at idle speed.

• Plug [A] the vacuum switch valve hose end with your fin-

ger and feel vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for

leak. If there is no leak, check the vacuum switch valve

or air suction valve (see Engine Top End chapter).

Engine Top End

Valve Clearance Inspection

NOTE

○Valve clearance must be checked and adjusted when

the engine is cold (room temperature).

• Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-

moval in the Engine Top End chapter)

Left Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

• Unscrew the two plugs [A], [B] on the alternator cover.

Special Tool - Filler Cap Driver: 57001-1454

• Check the valve clearance when the pistons are at TDC.

○The pistons are numbered beginning with the engine left

side.

• Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the "2/T" [A] mark on the timing

rotor is aligned with the projection [B] in the inspection

window on the alternator cover.

○Measure the valve clearance of the valves for which the

cam [A] are turned away from each other.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Using the thickness gauge [A], measure the valve clear-

ance between cam and valve lifter.

Valve Clearance

Standard:

Exhaust

0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)

Inlet

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

○Each piston has two inlet and two exhaust valves. Mea-

sure these two inlet or exhaust valves at the same crank-

shaft position.

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #1 piston, and

Exhaust valve clearances of #1 piston

NOTE

○Check the valve clearance using this method only.

Checking the clearance at any other cam position may

result in improper valve clearance.

Valve Clearance Measuring Position

#2 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #2 piston, and

Exhaust valve clearances of #2 piston

If the valve clearance is not with in the specified range,

first record the clearance, and adjust it.

Valve Clearance Adjustment

• To change the valve clearance, remove the camshaft

chain tensioner, camshafts and valve lifters. Replace the

shim with one of a different thickness.

NOTE

○Mark and record the locations of the valve lifters and

shims so that they can be reinstalled in their original

positions.

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

• Clean the shim to remove any dust or oil.

• Measure the thickness of the removed shim [A].

• Select a new shim thickness calculation as follows.

a +b -c = d

[a] Present Shim Thickness

[b] Measured Valve Clearance

[c] Specified Valve Clearance (Mean Value = 0.255 mm

(Exhaust), 0.195 mm (Inlet))

[d] Replace Shim Thickness

Example (Inlet):

2.90 + 0.45 - 0.195 = 3.155 mm

○Exchange the shim for the 3.175 size shim.

NOTICE

Don’t use the shims for another models. This could

cause wear of the valve stem end, and valve stem

damage.

Adjustment Shims

Thickness

Part Number

Mark

2.50

92180-1014

2.55

92180-1016

2.60

92180-1018

2.65

92180-1020

2.70

92180-1022

2.75

92180-1024

2.80

92180-1026

2.85

92180-1028

2.90

92180-1030

2.95

92180-1032

3.00

92180-1034

3.05

92180-1036

3.10

92180-1038

3.15

92180-1040

3.20

92180-1042

3.25

92180-1044

3.30

92180-1046

3.35

92180-1048

3.40

92180-1050

3.45

92180-1052

3.50

92180-1054

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clutch

Clutch Operation Inspection

• Pull the clutch lever just enough to take up the free play

[A].

• Measure the gap between the lever and the lever holder.

If the gap is too wide, the clutch may not release fully. If

the gap is too narrow, the clutch may not engage fully. In

either case, adjust it.

Clutch Lever Free Play

Standard:

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

WARNING

The engine and exhaust system get extremely hot

during normal operation and can cause serious

burns. Never touch the engine or exhaust pipe

during clutch adjustment.

• Turn the adjuster [B] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [A]

of threads are visible.

• Remove the right lower fairing (see Lower Fairing Re-

moval in the Frame chapter).

• Slide the dust cover [A] from the clutch cable lower end

out of place.

• Loosen both adjusting nuts [B] at the clutch cover as far

as they will go.

• Pull the clutch outer cable [C] tight and tighten the adjust-

ing nuts against the bracket [D].

• Slip the rubber dust cover back onto place.

• Turn the adjuster at the clutch lever until the free play is

correct.

WARNING

Too much cable play can prevent clutch disengage-

ment and cause an accident resulting in serious in-

jury or death. When adjusting the clutch or replac-

ing the cable, be sure the upper end of the clutch

outer cable is fully seated in its fitting, or it could

slip into place later, creating enough cable play to

prevent clutch disengagement.

• After the adjustment, start the engine and check that the

clutch does not slip and that it releases properly.

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

Wheels/Tires

Air Pressure Inspection

• Remove the air valve cap.

• Measure the tire air pressure with an air pressure gauge

[A] when the tires are cold (that is, when the motorcycle

has not been ridden more than a mile during the past 3

hours).

• Install the air valve cap.

Adjust the tire air pressure according to the specifications

if necessary.

Air Pressure (when Cold)

Front:

Up to 170 kg (375 lb)

200 kPa (2.00 kgf/cm², 28 psi)

Rear:

Up to 170 kg (375 lb)

225 kPa (2.25 kgf/cm², 32 psi)

Wheel/Tire Damage Inspection

• Remove any imbedded stones [A] or other foreign parti-

cles [B] from tread.

• Visually inspect the tire for cracks and cuts, and replace

the tire if necessary. Swelling or high spots indicate inter-

nal damage, requiring tire replacement.

• Visually inspect the wheel for cracks, cuts and dents dam-

age.

If any damage is found, replace the wheel if necessary.

Tire Tread Wear, Abnormal Wear Inspection

As the tire tread wears down, the tire becomes more sus-

ceptible to puncture and failure. An accepted estimate is

that 90% of all tire failures occur during the last 10% of tread

life (90% worn). So it is false economy and unsafe to use

the tires until they are bald.

• Measure the tread depth at the center of the tread with a

depth gauge [A]. Since the tire may wear unevenly, take

measurement at several places.

If any measurement is less than the service limit, replace

the tire (see Tire Removal/Installation in the Wheels/Tires

chapter).

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tread Depth

Standard:

Front:

BRIDGESTONE

4.6 mm (0.181 in.)

DUNLOP

4.5 mm (0.177 in.)

IRC

4.2 mm (0.165 in.)

Rear:

BRIDGESTONE

7.0 mm (0.276 in.)

DUNLOP

7.4 mm (0.291 in.)

IRC

6.5 mm (0.256 in.)

Service Limit:

Front

1 mm (0.04 in.)

Rear

2 mm (0.08 in.)

(Up to 130 km/h (80 mph))

3 mm (0.12 in.)

(Over 130 km/h (80 mph))

WARNING

Some replacement tires may adversely affect han-

dling and cause an accident resulting in serious in-

jury or death. To ensure proper handling and sta-

bility, use only the recommended standard tires for

replacement, inflated to the standard pressure.

NOTE

○Most countries may have their own regulations a mini-

mum tire tread depth: be sure to follow them.

○Check and balance the wheel when a tire is replaced

with a new one.

Wheel Bearing Damage Inspection

• Raise the front wheel off the ground with jack (see Front

Wheel Removal in the Wheels/Tires chapter).

• Turn the handlebar all the way to the right or left.

• Inspect the roughness of the front wheel bearing by push-

ing and pulling [A] the wheel.

• Spin [B] the front wheel lightly, and check for smoothly

turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the front

wheel and inspect the wheel bearing (see Front Wheel

Removal, Hub Bearing Inspection in the Wheels/Tires

chapter).

• Raise the rear wheel off the ground with stand (see Rear

Wheel Removal in the Wheels/Tires chapter).

• Inspect the roughness of the rear wheel bearing by push-

ing and pulling [A] the wheel.

• Spin [B] the rear wheel lightly, and check for smoothly

turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the rear

wheel and inspect the wheel bearing (see Rear Wheel Re-

moval, Hub Bearing Inspection in the Wheels/Tires chap-

ter) and coupling (see Coupling Bearing Inspection in the

Final Drive chapter).

PERIODIC MAINTENANCE 2-29

Periodic Maintenance Procedures

Drive Train

Drive Chain Lubrication Condition Inspection

• If a special lubricant is not available, a heavy oil such as

SAE 90 is preferred to a lighter oil because it will stay on

the chain longer and provide better lubrication.

• If the chain appears especially dirty, clean it before lubri-

cation.

NOTICE

The O-rings between the side plates seal in the lu-

bricant between the pin and the bushing. To avoid

damaging the O-rings and resultant loss of lubri-

cant, observe the following rules.

Use only kerosene or diesel oil for cleaning an O

-ring drive chain. Any other cleaning solution such

as gasoline or trichloroethylene will cause deterio-

ration and swelling of the O-ring. Immediately blow

the chain dry with compressed air after cleaning.

Complete cleaning and drying the chain within 10

minutes.

• Apply oil to the sides of the rollers so that oil will penetrate

to the rollers and bushings. Apply the oil to the O-rings so

that the O-rings will be coated with oil.

• Wipe off any excess oil.

Oil Applied Areas [A]

O-rings [B]

Drive Chain Slack Inspection

NOTE

○Check the slack with the motorcycle setting on its side-

stand.

○Clean the chain if it is dirty, and lubricate it if it appears

dry.

• Check the wheel alignment (see Wheel Alignment Inspec-

tion).

• Rotate the rear wheel to find the position where the chain

is tightest.

• Measure the vertical movement (chain slack) [A] midway

between the sprockets.

If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard:

20 ∼ 30 mm (0.8 ∼ 1.2 in.)

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Drive Chain Slack Adjustment

• Remove the cotter pin [A], and loosen the axle nut [B].

• Loosen the both chain adjuster locknuts [C].

If the chain is too loose, turn in the left and right chain

adjuster nuts [D] evenly.

If the chain is too tight, turn out the left and right chain

adjuster nuts evenly, and kick the wheel forward.

• Turn both chain adjuster nuts evenly until the drive chain

has the correct amount of slack. To keep the chain

and wheel properly aligned, the notch [E] on the left

wheel alignment indicator [F] should align with the same

swingarm mark or position [G] that the right indicator

notch aligns with.

WARNING

Misalignment of the wheel will result in abnormal

wear and may result in an unsafe riding condition.

Be sure the wheel is properly aligned.

• Tighten both chain adjuster locknuts securely.

• Tighten the axle nut.

Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)

• Turn the wheel, measure the chain slack again at the tight-

est position, and readjust if necessary.

• Insert a new cotter pin [A].

NOTE

○When inserting the cotter pin, if the slots in the nut do

not align with the cotter pin hole in the axle, tighten the

nut clockwise [B] up to next alignment.

○It should be within 30°.

○Loosen once and tighten again when the slot goes past

the nearest hole.

• Bend the cotter pin [A] over the nut [B].

WARNING

A loose axle nut can lead to an accident resulting in

serious injury or death. Tighten the axle nut to the

proper torque and install a new cotter pin.

PERIODIC MAINTENANCE 2-31

Periodic Maintenance Procedures

Wheel Alignment Inspection

• Check that the notch [A] on the right wheel alignment indi-

cator [B] aligns with the same swingarm mark or position

[C] that the left alignment indicator notch aligns with.

If they do not, adjust the chain slack and align the wheel

alignment (see Drive Chain Slack Adjustment).

NOTE

○Wheel alignment can be also checked using the

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal

wear and may result in an unsafe riding condition.

Be sure the wheel is properly aligned.

Drive Chain Wear Inspection

• Remove:

Chain Cover (see Swingarm Removal in the Suspension

chapter)

• Rotate the rear wheel to inspect the drive chain for dam-

aged rollers, and loose pins and links.

If there is any irregularity, replace the drive chain.

Lubricate the drive chain if it appears dry.

• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)

weight [A] on the chain.

• Measure the length of 20 links [B] on the straight part [C] of

the chain from the pin center of the 1st pin to the pin center

of the 21st pin. Since the chain may wear unevenly, take

measurements at several places.

If any measurements exceed the service limit, replace the

chain. Also, replace the front and rear sprockets when the

drive chain is replaced.

Drive Chain 20-link Length

Standard:

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit:

EX250J8 ∼ JA

323 mm (12.72 in.)

EX250JB ∼ JC

319 mm (12.56 in.)

WARNING

A chain that breaks or jumps off the sprockets

could snag on the engine sprocket or lock the

rear wheel, severely damaging the motorcycle and

causing it to go out of control. Inspect the chain for

damage and proper adjustment before each ride.

If chain wear exceeds the service limit, replace it

with the standard chain. It is an endless type and

should not be cut for installation.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Standard Chain

Make:

EX250J8 ∼ JA

ENUMA

EX250JB ∼ JC

DAIDO

Type:

EX250J8 ∼ JA

EK520SR-O₂

EX250JB ∼ JC

DID 520VP2-T

Link:

106 links

Chain Guide Inspection

• Remove:

Swingarm (see Swingarm Removal in the Suspension

chapter)

• Visually inspect the chain guide [A].

Replace the chain guide if it shows any signs of abnormal

wear or damage.

Brake System

Brake Fluid Leak (Brake Hose and Pipe) Inspection

• Apply the brake lever or pedal and inspect the brake fluid

leak from the brake hoses [A] and fittings [B].

If the brake fluid leaked from any position, inspect or re-

place the problem part.

Brake Hose and Pipe Damage and Installation

Condition Inspection

• Inspect the brake hoses and fittings for deterioration,

cracks and signs of leakage.

○The high pressure inside the brake line can cause fluid to

leak [A] or the hose to burst if the line is not properly main-

tained. Bend and twist the rubber hose while examining

it.

Replace the hose and pipe if any crack [B], bulge [C] or

leakage is noticed.

Tighten any brake hose banjo bolts.

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

• Inspect the brake hose routing.

If any brake hose routing is incorrect, route the brake hose

according to Cable, Wire, and Hose Routing section in the

Appendix chapter.

PERIODIC MAINTENANCE 2-33

Periodic Maintenance Procedures

Brake Operation Inspection

• Inspect the operation of the front and rear brake by run-

ning the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake

system.

WARNING

When test riding the vehicle, be aware of surround-

ing traffic for your safety.

Brake Fluid Level Inspection

• Check that the brake fluid level in the front brake reservoir

[A] is above the lower level line [B].

NOTE

○Hold the reservoir horizontal by turning the handlebar

when checking brake fluid level.

If the fluid level is lower than the lower level line, fill the

reservoir to the upper level line [C] in the reservoir.

• Check that the brake fluid level in the rear brake reservoir

[A] is above the lower level line [B].

If the fluid level is lower than the lower level line, fill the

reservoir to the upper level line [C].

WARNING

Mixing brands and types of brake fluid can reduce

the brake system’s effectiveness and cause an ac-

cident resulting in injury or death. Do not mix two

brands of brake fluid. Change the brake fluid in the

brake line completely if the brake fluid must be re-

filled but the type and brand of the brake fluid that

is already in the reservoir are unidentified.

Recommended Disc Brake Fluid

Grade:

DOT4

• Follow the procedure below to install the rear brake fluid

reservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [B] clock-

wise [C] by hand until slight resistance is felt indicating

that the cap is seated on the reservoir body, then tighten

the cap an additional 1/6 turn [D] while holding the brake

fluid reservoir body [A].

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Pad Wear Inspection

• Check the lining thickness [A] of the pads in each caliper.

If the lining thickness of either pad is less than the service

limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

Standard:

4.5 mm (0.18 in.)

Service Limit:

1 mm (0.04 in.)

Brake Light Switch Operation Inspection

• Turn on the ignition switch.

• The brake light [A] should go on when the brake lever is

applied or after the brake pedal is depressed about 10

mm (0.39 in.).

If it does not, adjust the brake light switch.

• Disconnect the connector [A].

• Turn the brake light switch to adjust the switch.

• Connect the connector.

If it does not go on, inspect or replace the following items.

Battery (see Charging Condition Inspection in the Elec-

trical System chapter)

Brake Light (see Tail/Brake Light Removal in the Electri-

cal System chapter)

Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-

spection in the Electrical System chapter)

Front Brake Light Switch [A] (see Switch Inspection in

the Electrical System chapter)

Rear Brake Light Switch (see Switch Inspection in the

Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

PERIODIC MAINTENANCE 2-35

Periodic Maintenance Procedures

Suspensions

Front Forks/Rear Shock Absorber Operation

Inspection

• Pump the forks down and up [A] 4 or 5 times, and inspect

the smooth stroke.

If the forks do not smoothly or noise is found, inspect the

fork oil level or fork clamps (see Front Fork Oil Change in

the Suspension chapter).

• Pump the seat down and up [A] 4 or 5 times, and inspect

the smooth stroke.

If the shock absorber does not smoothly stroke or noise

is found, inspect the oil leak (see Rear Shock Absorber

Oil Leak Inspection).

Front Fork Oil Leak Inspection

• Visually inspect the front forks [A] for oil leakage.

Replace or repair any defective parts, if necessary.

Rear Shock Absorber Oil Leak Inspection

• Visually inspect the shock absorber [A] for oil leakage.

If the oil leakage is found on it, replace the shock absorber

with a new one.

Rocker Arm Operation Inspection

• Pump the seat down and up 4 or 5 times, and inspect the

smooth stroke.

If the rocker arm [A] does not smoothly stroke or noise

is found, inspect the fasteners and bushings (see Rocker

Arm/Tie-Rod Bushing, Sleeve Inspection in the Suspen-

sion chapter).

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Tie-Rod Operation Inspection

• Pump the seat down and up 4 or 5 times, and inspect the

smooth stroke.

If the tie-rod [A] do not smoothly stroke or noise is found,

inspect the fasteners and tie-rod bushings (see Rocker

Arm/Tie-Rod Bushing, Sleeve Inspection in the Suspen-

sion chapter).

Swingarm Pivot Lubrication

• Remove the swingarm bearing (see Swingarm Bearing

Removal in the Suspension chapter).

• Supply grease to the needle bearings and grease seals

in accordance with the Periodic Maintenance chart.

Steering System

Steering Play Inspection

• Raise the front wheel off the ground with jack (see Front

Wheel Removal in the Wheels/Tires chapter).

• With the front wheel pointing straight ahead, alternately

tap each end of the handlebar. The front wheel should

swing fully left and right from the force of gravity until the

fork hits the stop.

If the wheel binds or catches before the stop, the steering

is too tight.

• Feel for steering looseness by pushing and pulling the

forks.

If you feel looseness, the steering is too loose.

NOTE

○The cables and wiring will have some effect on the mo-

tion of the fork which must be taken into account.

○Be sure the wires and cables are properly routed.

○The bearings must be in good condition and properly

lubricated in order for any test to be valid.

PERIODIC MAINTENANCE 2-37

Periodic Maintenance Procedures

Steering Play Adjustment

• Loosen:

Front Fork Clamp Bolts (lower) (both sides)

Stem Head Bolt [A]

• Adjust the steering.

If the steering is too loose, tighten the steering stem nut

a fraction of a turn using the special tool [B].

If the steering is too tight, loosen the stem nut a fraction

of a turn.

Special Tool - Steering Stem Nut Wrench: 57001-1100

NOTE

○Turn the stem nut 1/8 turn at a time maximum.

• Tighten:

Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32

ft·lb)

Front Fork Clamp Bolts (lower): 30 N·m (3.1 kgf·m,

22 ft·lb)

• Check the steering again.

If the steering is still too tight or too loose, repeat the ad-

justment.

Steering Stem Bearing Lubrication

• Remove the steering stem (see Stem, Stem Bearing Re-

moval in the Steering chapter).

• Using a high-flash point solvent, wash the upper and

lower ball bearings, and wipe the upper and lower outer

races, which are press-fitted into the frame head pipe,

clean off grease and dirt.

• Visually check the outer races and the ball bearings.

Replace them if they show wear or damage.

• Apply a light coat of grease to the upper and lower [A] ball

bearings and outer races.

• Install the steering stem (see Stem, Stem Bearing Instal-

lation in the Steering chapter).

• Adjust the steering (see Steering Play Adjustment).

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Electrical System

Lights and Switches Operation Inspection

First Step

• Turn on the ignition switch.

• The following lights should go on according to below table.

Taillight [A]

goes on

License Plate Light [B]

goes on

Meter Panel Lights [C]

goes on

Neutral Indicator Light [D]

goes on

Oil Pressure Warning Indicator Light [E]

goes on

Water Temperature Warning Indicator Light

goes on

[F]

If the light does not go on, inspect or replace the following

item.

Battery (see Charging Condition Inspection in the Elec-

trical System chapter)

Applicable Bulb (see Wiring Diagram in the Electrical

System chapter)

Meter Unit for Meter Lights (see Meter Unit Inspection in

the Electrical System chapter)

Meter Unit for Neutral Indicator Light (see Meter Unit

Inspection in the Electrical System chapter)

Meter Unit for Oil Pressure Warning Indicator Light (see

Meter Unit Inspection in the Electrical System chapter)

Meter Unit for Water Temperature Warning Indicator

Light (see Meter Unit Inspection in the Electrical System

chapter)

Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-

spection in the Electrical System chapter)

Ignition Switch (see Switch Inspection in the Electrical

System chapter)

Neutral Switch (see Switch Inspection in the Electrical

System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

• Turn off the ignition switch.

• The all lights should go off.

If the light does not go off, replace the ignition switch.

PERIODIC MAINTENANCE 2-39

Periodic Maintenance Procedures

Second Step

• Turn on the turn signal switch [A] (left or right position).

• The left or right turn signal lights [B] (front and rear) ac-

cording to the switch position should flash.

• The turn signal indicator light [C] in the meter unit should

flash.

If the each light does not flash, inspect or replace the

following item.

Turn Signal Light Bulb (see Turn Signal Light Bulb Re-

placement in the Electrical System chapter)

Meter Unit for Turn Signal Light Indicator Light (see Me-

ter Unit Inspection in the Electrical System chapter)

Turn Signal Relay Fuse 10 A (see Fuse Inspection in the

Electrical System chapter)

Turn Signal Switch (see Switch Inspection in the Electri-

cal System chapter)

Turn Signal Relay (see Turn Signal Relay Inspection in

the Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

• Push the turn signal switch.

• The turn signal lights and indicator light should go off.

If the light does not go off, inspect or replace the following

item.

Turn Signal Switch (see Switch Inspection in the Electri-

cal System chapter)

Turn Signal Relay (see Turn Signal Relay Inspection in

the Electrical System chapter)

Third Step

• Set the dimmer switch [A] to low beam position.

• Start the engine.

• The low beam headlight should go on.

If the low beam headlight does not go on, inspect or re-

place the following item.

Headlight Low Beam Bulb (see Headlight Bulb Replace-

ment in the Electrical System chapter)

Headlight Fuse 10 A (see Fuse Inspection in the Electri-

cal System chapter)

Dimmer Switch (see Switch Inspection in the Electrical

System chapter)

Headlight Relay (see Relay Circuit Inspection in the

Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Set the dimmer switch to high beam position.

• The low beam [A] and high beam [B] headlights should

go on.

• The high beam indicator light [C] should go on.

If the high beam headlight and/or high beam indicator light

does not go on, inspect or replace the following item.

Headlight High Beam Bulb (see Headlight Bulb Replace-

ment in the Electrical System chapter)

Dimmer Switch (see Switch Inspection in the Electrical

System chapter)

• Turn off the engine stop switch.

• The low beam and high beam headlights should stay go-

ing on.

If the headlights and high beam indicator light does go off,

inspect or replace the following item.

Headlight Relay (see Relay Circuit Inspection in the

Electrical System chapter)

• Turn off the ignition switch.

• The headlights and high beam indicator light should go

off.

Headlight Aiming Inspection

• Inspect the headlight beam for aiming.

If the headlight beam points to one side rather than

straight ahead, adjust the horizontal beam.

Headlight Beam Horizontal Adjustment

• Turn the horizontal adjuster [A] on the headlight with the

screwdriver in or out until the beam points straight ahead.

If the headlight beam points too low or high, adjust the

vertical beam.

Headlight Beam Vertical Adjustment

• Turn the vertical adjuster [A] on the headlight with the

screwdriver in or out to adjust the headlight vertically.

PERIODIC MAINTENANCE 2-41

Periodic Maintenance Procedures

NOTE

○ON high beam, the brightest points should be slightly

below horizontal with the motorcycle on its wheels and

the rider seated. Adjust the headlight to the proper an-

gle according to local regulations.

○For US model, the proper angle is 0.4 degrees below

horizontal. This is 50 mm (2 in.) drop at 7.6 m (25

ft) measured from the center of the headlight with the

motorcycle on its wheels and the rider seated.

50 mm (2 in.) [A]

Center of Brightest Spot [B]

7.6 m (25 ft) [C]

Low Beam [D]

Height of Headlight Center [E]

High Beam [F]

Sidestand Switch Operation Inspection

• Inspect the sidestand switch [A] operation accordance to

below table.

Sidestand Switch Operation

Gear

Clutch

Engine

Sidestand

Position

Lever

Start

Run

Continue

Neutral

Released

Starts

running

Continue

Neutral

Pulled in

Starts

running

Doesn’t

In Gear

Released

Stops

start

Continue

In Gear

Pulled in

Starts

running

Continue

Down

Neutral

Released

Starts

running

Continue

Down

Neutral

Pulled in

Starts

running

Doesn’t

Down

In Gear

Released

Stops

start

Doesn’t

Down

In Gear

Pulled in

Stops

start

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If the sidestand switch operation does not work, inspect

or replace the following item.

Battery (see Charging Condition Inspection in the Elec-

trical System chapter)

Main Fuse 30 A (see Fuse Inspection in the Electrical

System chapter)

Ignition Fuse 10 A (see Fuse Inspection in the Electrical

System chapter)

Ignition Switch (see Switch Inspection in the Electrical

System chapter)

Sidestand Switch (see Switch Inspection in the Electrical

System chapter)

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

Starter Button (see Switch Inspection in the Electrical

System chapter)

Neutral Switch (see Switch Inspection in the Electrical

System chapter)

Starter Relay (see Starter Relay Inspection in the Elec-

trical System chapter)

Starter Circuit Relay (see Relay Circuit Inspection in the

Electrical System chapter)

Harness (see Wiring Inspection in the Electrical System

chapter)

If the all parts are good condition, replace the IC Igniter.

Engine Stop Switch Operation Inspection

First Step

• Turn on the ignition switch.

• Set the neutral position.

• Turn the engine stop switch to stop position [A].

• Push the starter button.

• The engine does not start.

If the engine starts, inspect or replace the following item.

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

Second Step

• Turn on the ignition switch.

• Set the neutral position.

• Turn the engine stop switch to run position [A].

• Push the starter button and run the engine.

• Turn the engine stop switch to stop position.

• Immediately the engine should be stop.

If the engine does not stop, inspect or replace the follow-

ing item.

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)

If the engine stop switch is good condition, replace the IC

Igniter.

PERIODIC MAINTENANCE 2-43

Periodic Maintenance Procedures

Others

Chassis Parts Lubrication

• Before lubricating each part, clean off any rusty spots with

rust remover and wipe off any grease, oil, dirt, or grime.

• Lubricate the points listed below with indicated lubricant.

NOTE

○Whenever the vehicle has been operated under

wet or rainy conditions, or especially after using a

high-pressure water spray, perform the general lubri-

cation.

Pivots: Lubricate with Grease.

Brake Lever

Brake Pedal

Clutch Lever

Rear Brake Joint Pin

Sidestand

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]

Throttle Inner Cable Upper and Lower Ends

Cables: Lubricate with Rust Inhibitor.

Clutch Cable

Throttle Cables

• Lubricate the cables by seeping the oil between the cable

and housing.

○The cable may be lubricated by using a commercially

available pressure cable lubricator with an aerosol cable

lubricant.

• With the cable disconnected at both ends, the inner cable

should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable

is frayed [B], or if the cable housing is kinked [C], replace

the cable.

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Bolts, Nuts and Fasteners Tightness Inspection

• Check the tightness of the bolts and nuts listed here. Also,

check to see that each cotter pin is in place and in good

condition.

NOTE

○For the engine fasteners, check the tightness of them

when the engine is cold (at room temperature).

If there are loose fasteners, retighten them to the spec-

ified torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not in the appropriate chapter,

see the Standard Torque Table. For each fastener, first

loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Bolt, Nut and Fastener to be checked

Engine:

Clutch Lever Pivot Nut

Engine Mounting Bolts and Nuts

Exhaust Pipe Manifold Holder Nuts

Muffler Body Mounting Bolts

Wheels:

Front Axle

Rear Axle Nut

Rear Axle Nut Cotter Pin

Brakes:

Brake Lever Pivot Nut

Brake Pedal Bolt

Brake Rod Joint Cotter Pin

Caliper Mounting Bolts

Front Master Cylinder Clamp Bolts

Rear Master Cylinder Mounting Bolts

Suspension:

Front Fork Clamp Bolts

Rear Shock Absorber Bolt and Nut

Swingarm Pivot Shaft Nut

Steering:

Steering Stem Head Bolt

Handlebar Holder Bolts

Others:

Footpeg Stay Bolts

Front Fender Bolts

Sidestand Bolt

PERIODIC MAINTENANCE 2-45

Periodic Maintenance Procedures

Replacement Parts

Air Cleaner Element Replacement

• Refer to the Air Cleaner Element Cleaning (see Air

Cleaner Element Cleaning).

Fuel Hose Replacement

• Refer to Fuel Hose Inspection (see Fuel Hose Inspection).

Coolant Change

WARNING

Coolant can be extremely hot and cause severe

burns, is toxic and very slippery. Do not remove

the radiator cap or attempt to change the coolant

when the engine is hot; allow it cool completely.

Immediately wipe any spilled coolant from tires,

frame, engine or other painted parts. Do not ingest

coolant.

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Radiator Cap [A]

• Place a container under the drain bolts [A] at the bottom

of the water pump cover and cylinder.

• Drain the coolant from the radiator and engine by remov-

ing the drain bolts.

Torque - Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Remove:

Hoses [A]

Mounting Bolts [B] and Reserve Tank [C]

• Remove the cap [D] and pour the coolant of the reserve

tank into the container.

• Install:

Hoses

Reserve Tank

• Tighten the drain bolt with the specified torque.

Torque - Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Fill the radiator up to the radiator filler neck [A] with

coolant, and install the radiator cap.

NOTE

○Pour in the coolant slowly so that it can expel the air

from the engine and radiator.

• Fill the reserve tank up to the full level line with coolant,

and install the cap.

NOTICE

Soft or distilled water must be used with the an-

tifreeze (see below for antifreeze) in the cooling sys-

tem.

If hard water is used in the system, it causes scales

accumulation in the water passages, and consider-

ably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (Recommended)

Soft Water:

50%

Coolant:

50%

Freezing Point: -35°C (-31°F)

Capacity:

1.5 L (1.59 US qt)

NOTE

○Choose a suitable mixture ratio by referring to the

coolant manufacturer’s directions.

PERIODIC MAINTENANCE 2-47

Periodic Maintenance Procedures

• Bleed the air from the cooling system as follows.

○Start the engine with the radiator cap removed and run it

until no more air bubbles [A] can be seen in the coolant.

○Tap the radiator hoses to force any air bubbles caught

inside.

○Stop the engine and add coolant up to the radiator filler

neck.

• Install the radiator cap.

• Start the engine, warm it up thoroughly until the radiator

fan turns on and then stop the engine.

• Check the coolant level in the reserve tank after the en-

gine cools down.

If the coolant level is lower than the low level line, add

coolant to the full level line.

NOTICE

Do not add more coolant above the full level line.

Radiator Hose and O-ring Replacement

• Drain the coolant (see Coolant Change).

• Remove:

Thermostat Housing [A] (see Water Pump Removal in

the Cooling System chapter)

Water Pump Cover [B] (see Water Pump Removal in the

Cooling System chapter)

Hoses [C]

Pipe [D]

O-rings [E]

• Apply grease to the new O-rings and install them.

• Install the new hoses and tighten the clamps securely.

• Fill the coolant (see Coolant Change).

• Check the cooling system for leaks.

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Engine Oil Change

WARNING

The engine and exhaust system get extremely hot

during normal operation and can cause serious

burns. Never touch the engine or exhaust pipe

during oil change.

• Warm up the engine sufficiently with the motorcycle

standing on its side stand, and stop the engine.

• Place an oil pan under the engine and remove the drain

bolt [A] to drain the oil.

• Replace the drain bolt gaskets with new ones if they are

damaged.

○The oil in the oil filter can be drained by removing the filter.

• After draining the oil, tighten the drain bolts.

Torque - Oil Drain Bolts: 19.6 N·m (2.0 kgf·m, 14.5 ft·lb)

Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5

ft·lb)

• Pour in the specified type and amount of oil.

Recommended Engine Oil

Type:

API SG, SH, SJ, SL or SM with JASO MA,

MA1 or MA2

Viscosity: SAE 10W - 40

Capacity:

1.3 L (1.4 US qt) (When filter is not removed)

1.6 L (1.7 US qt) (When filter is removed)

NOTE

○Do not add any chemical additive to the oil. Oils fulfilling

the above requirements are fully formulated and provide

adequate lubrication for both the engine and the clutch.

○Although 10W-40 engine oil is the recommended oil

for most conditions, the oil viscosity may need to be

changed to accommodate atmospheric conditions in

your riding area.

Oil Filter Replacement

• Drain the engine oil (see Engine Oil change).

• Remove the oil filter mounting bolt [A].

PERIODIC MAINTENANCE 2-49

Periodic Maintenance Procedures

• Replace the oil filter with a new one.

• Apply engine oil to the O-rings [A] before installation after

inspecting its damage.

• Install the oil filter mounting bolt [B] with a specified

torque.

Torque - Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5

ft·lb)

• Pour in the specified type and amount of oil (see Engine

Oil Change).

Brake Hose and Pipe Replacement

NOTICE

Brake fluid quickly ruins painted plastic surfaces;

any spilled fluid should be completely washed away

immediately.

• Remove the banjo bolts.

• When removing the brake hose, take care not to spill the

brake fluid on the painted or plastic parts.

• When removing the brake hoses [A], temporarily secure

the end of the brake hose to some high place to keep fluid

loss to a minimum.

• Immediately wash away any brake fluid that spills.

• There are washers on each side of the brake hose fitting.

Replace them with new ones when installing.

• Tighten:

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

• When installing the hoses [A], avoid sharp bending, kink-

ing, flatting or twisting, and route the hoses according to

Cable, Wire, and Hose Routing section in the Appendix

chapter.

• Fill the brake line after installing the brake hose (see

Brake Fluid Change).

Brake Fluid Change

NOTE

○The procedure to change the front brake fluid is as fol-

lows. Changing the rear brake fluid is the same as for

the front brake.

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Level the brake fluid reservoir.

• Remove the reservoir cap and diaphragm.

• Remove the rubber cap from the bleed valve [A] on the

caliper.

• Attach a clear plastic hose [B] to the bleed valve, and run

the other end of the hose into a container.

• Fill the reservoir with fresh specified brake fluid.

• Change the brake fluid.

○Repeat this operation until fresh brake fluid comes out

from the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A].

2. Apply the brake and hold it [B].

3. Close the bleed valve [C].

4. Release the brake [D].

NOTE

○The fluid level must be checked often during the chang-

ing operation and replenished with fresh brake fluid. If

the fluid in the reservoir runs out any time during the

changing operation, the brakes will need to be bled

since air will have entered the brake line.

○Front Brake: Repeat the above steps for the other

caliper.

• Remove the clear plastic hose.

• Install the diaphragm and reservoir cap.

• Tighten:

Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15

kgf·m, 13 in·lb)

• Follow the procedure below to install the rear brake fluid

reservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [B] clock-

wise [C] by hand until slight resistance is felt indicating

that the cap is seated on the reservoir body, then tighten

the cap an additional 1/6 turn [D] while holding the brake

fluid reservoir body [A].

• Tighten the bleed valve, and install the rubber cap.

Torque - Bleed Valve: 5.5 N·m (0.55 kgf·m, 49 in·lb)

• After changing the fluid, check the brake for good braking

power, no brake drag, and no fluid leakage.

If necessary, bleed the air from the lines.

PERIODIC MAINTENANCE 2-51

Periodic Maintenance Procedures

Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

• Remove the front master cylinder (see Front Master Cylin-

der Removal in the Brakes chapter).

• Remove the reservoir cap and diaphragm, and pour the

brake fluid into a container.

• Unscrew the locknut and pivot bolt, and remove the brake

lever.

• Pull the dust cover out of place, and remove the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

• Pull out the piston [A], secondary cup [B], primary cup [C],

and return spring [D].

NOTICE

Do not remove the secondary cup from the piston

since removal will damage it.

Rear Master Cylinder Disassembly

NOTE

○Do not remove the push rod clevis for master cylinder

disassembly since removal requires brake position ad-

justment.

• Remove the rear master cylinder (see Rear Master Cylin-

der Removal in the Brakes chapter).

• Remove the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

• Pull out the push rod with the piston stop.

• Take off the piston [A], secondary cup [B], primary cup [C]

and return spring [D].

• Remove the circlip [F] and pull out the brake hose con-

nector [G] and O-ring [H].

Special Tool - Inside Circlip Pliers: 57001-143

NOTICE

Do not remove the secondary cup from the piston

since removal will damage it.

Master Cylinder Assembly

• Before assembly, clean all parts including the master

cylinder with brake fluid or alcohol.

NOTICE

Except for the disc pads and disc, use only disc

brake fluid, isopropyl alcohol, or ethyl alcohol for

cleaning brake parts. Do not use any other fluid for

cleaning these parts. Gasoline, engine oil, or any

other petroleum distillate will cause deterioration of

the rubber parts. Oil spilled on any part will be diffi-

cult to wash off completely, and will eventually de-

teriorate the rubber used in the disc brake.

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Apply brake fluid to the removed parts and to the inner

wall of the cylinder.

• Take care not to scratch the piston or the inner wall of the

cylinder.

• Apply silicone grease (ex. PBC grease).

Brake Lever Pivot Bolt

Brake Lever Pivot Contact

Push Rod Contact (Rear)

Dust Cover

• Tighten:

Torque - Brake Lever Pivot Bolt:

1.0 N·m (0.10 kgf·m, 9

in·lb)

Brake Lever Pivot Bolt Locknut:

5.9 N·m (0.60

kgf·m, 52 in·lb)

Caliper Rubber Parts Replacement

Caliper Disassembly

• Remove a front Caliper (see Front Caliper Removal in the

Brakes chapter).

• Remove the pads and anti-rattle spring (see Pad Removal

in the Brakes chapter).

If compressed air is available, the piston may be removed

using compressed air as follows.

• Insert the wooden board of 5 mm (0.2 in.) thick inside the

caliper opening or cover the caliper opening with a clean,

heavy cloth [A].

• Lightly apply compressed air [B] to the hose joint opening

until the pistons hit the wooden board or heavy cloth.

WARNING

The piston in the brake caliper can crush hands and

fingers. Never place your hand or fingers in front of

the piston.

• Pull out the pistons by hand.

• Immediately wipe up any brake fluid that spills. It may ruin

painted or plated surfaces.

• Remove the dust seals and fluid seals.

• Remove the bleed valve and rubber cap.

NOTE

○If compressed air is not available, do as follows for both

calipers coincidentally, with the brake hose connected

to the caliper.

○Prepare a container for brake fluid, and perform the

work above it.

○Remove the spring and pads (see Brake Pad Removal).

○Pump the brake lever or pedal until the pistons come

out of the cylinders, and then disassemble the caliper.

PERIODIC MAINTENANCE 2-53

Periodic Maintenance Procedures

Caliper Assembly

• Clean the caliper parts except for the pads.

NOTICE

For cleaning of the parts, use only disc brake fluid,

ispopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.

Torque - Bleed Valve: 5.5 N·m (0.55 kgf·m, 49 in·lb)

• Replace the fluid seals [A] and dust seals [B] with new

one.

• Apply brake fluid to the fluid seals and dust seals, and

install them into the cylinder by hand.

• Apply brake fluid [A] to the outside of the pistons and push

them into each cylinder by hand without scratching the

cylinder and piston skirt.

• Apply silicone grease [B] to the caliper holder shaft and

holder holes, and install the caliper holder [C], rubber boot

[D] and dust cover [E].

• Install the anti-rattle spring [F] and pads in the caliper (see

Pad Installation in the Brakes chapter).

Spark Plug Replacement

• Remove:

Spark Plugs (see Spark Plug Removal in the Electrical

System chapter)

• Remove the spark plugs using the 16 mm plug wrench

[A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0044

• Insert the spark plug vertically into the plug hole with the

spark plug installed in the plug wrench [A].

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0044

• Tighten:

Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)

• Install:

Spark Plugs (see Spark Plug Installation in the Electrical

System chapter)

FUEL SYSTEM 3-1

Fuel System

Table of Contents

Exploded View

3-3

Exploded View (EX250J8)

3-8

Exploded View (EX250J9 ∼ JC)

3-10

Specifications

3-12

Special Tools

3-13

Throttle Grip and Cables

3-14

Free Play Inspection

3-14

Free Play Adjustment

3-14

Throttle Cable Removal

3-14

Throttle Cable Installation

3-14

Throttle Cable Lubrication

3-14

Choke Cable

3-15

Free Play Inspection

3-15

Free Play Adjustment

3-15

Choke Cable Removal

3-15

Choke Cable Installation

3-15

Choke Cable Lubrication and Inspection

3-15

Carburetors

3-16

Idle Speed Inspection

3-16

Idle Speed Adjustment

3-16

Engine Vacuum Synchronization Inspection

3-16

Engine Vacuum Synchronization Adjustment

3-16

Pilot Screw Adjustment

3-16

Service Fuel Level Inspection

3-17

Service Fuel Level Adjustment

3-18

Fuel System Cleanliness Inspection

3-19

Carburetor Removal

3-20

Carburetor Installation

3-21

Carburetor Separation

3-21

Carburetor Joining

3-21

Carburetor Disassembly

3-23

Carburetor Assembly

3-23

Carburetor Cleaning

3-24

Carburetor Inspection

3-25

Air Cleaner

3-27

Air Cleaner Element Removal

3-27

Air Cleaner Element Installation

3-27

Air Cleaner Housing Removal

3-27

Air Cleaner Housing Installation

3-28

Air Cleaner Housing Disassembly

3-28

Air Cleaner Housing Assembly

3-28

Oil Draining

3-29

Fuel Tank

3-30

Fuel Tank Removal

3-30

Fuel Tank Installation

3-30

Fuel Tap Removal

3-31

Fuel Tap Installation

3-31

Fuel Tank and Tap Cleaning

3-31

Fuel Tap Inspection

3-32

Fuel Tank and Cap Inspection

3-32

3-12 FUEL SYSTEM

Specifications

Item

Standard

Throttle Grip and Cable

Throttle Grip Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Choke Cable Free Play

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Carburetor

Make, Type

Keihin, CVK30

Main Jet

#98

Optional Main Jet

#92, 95, 100, 102

Main Air Jet

#100

Jet Needle

#L: N9VU, #R: N9VW

Needle Jet

Pilot Jet

#38

Pilot Air Jet

#100

Starter Jet

#48

Pilot Screw (turns out)

#L: 2 1/2, #R: 1 3/4

Throttle Valve

11° 00’

Idle Speed

1 300 ±50 r/min (rpm)

Carburetor Synchronization Vacuum

Less than 2.7 kPa (2 cmHg) difference between two

carburetors.

Service Fuel Level

0.5 ±1 mm (0.02 ±0.04 in.) above the mating surface of

carburetor float bowl.

Float Height

17 ±2 mm (0.67 ±0.08 in.)

Air Cleaner Element

Type

Polyurethane foam

3-14 FUEL SYSTEM

Throttle Grip and Cables

Free Play Inspection

• Refer to Throttle Control System Inspection in the Peri-

odic Maintenance chapter (see Throttle Control System

Inspection in the Periodic Maintenance chapter).

Free Play Adjustment

• Refer to Throttle Control System Inspection in the Peri-

odic Maintenance chapter (see Throttle Control System

Inspection in the Periodic Maintenance chapter).

Throttle Cable Removal

• Split the right handlebar switch housing [A] removing the

screws [B], and remove the throttle cable upper ends from

the throttle grip.

• Remove:

Front Seat (see Front Seat Removal in the Frame chap-

ter)

Side Cover (see Side Cover Removal in the Frame chap-

ter)

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

• Loosen the locknuts [A] and remove the lower end of the

accelerator cable [B] from the pulley.

• Loosen the locknuts [C] and remove the lower end of the

decelerator cable [D] from the pulley.

• Pull out the throttle cables upward

Throttle Cable Installation

• Install the throttle cables in accordance with the Cable,

Wire and Hose Routing in the Appendix chapter.

• Install the accelerator cable first and then decelerator ca-

ble.

• After installation, adjust each cable properly (see Throttle

Cable Inspection in the Periodic Maintenance chapter).

WARNING

Operation with incorrectly routed or improperly ad-

justed cables could result in an unsafe riding con-

dition. Be sure the cables are routed correctly and

properly adjusted.

Throttle Cable Lubrication

• Refer to Chassis Parts Lubrication Perform in the Peri-

odic Maintenance chapter (see Chassis Parts Lubrication

Perform in the Periodic Maintenance chapter).

FUEL SYSTEM 3-15

Choke Cable

Free Play Inspection

• Refer to Choke Operation Inspection in the Periodic Main-

tenance chapter (see Choke Operation in the Periodic

Maintenance chapter).

Free Play Adjustment

• Refer to Choke Operation Inspection in the Periodic Main-

tenance chapter (see Choke Operation in the Periodic

Maintenance chapter).

Choke Cable Removal

• Split the left handlebar switch housing [A], and remove

the choke cable [B] upper end from the choke lever [C].

• Remove:

Front Seat (see Front Seat Removal in the Frame chap-

ter)

Fuel Tank (see Fuel Tank Removal)

• Remove the choke cable end from the cable bracket of

carburetor.

• Pull out the choke cable upward.

Choke Cable Installation

• Install the choke cable in accordance with the Cable,

Wire, and Hose Routing section in Appendix chapter.

• After installation, adjust the cable properly.

WARNING

Operation with incorrectly routed or improperly ad-

justed cable could result in an unsafe riding condi-

tion. Be sure the cable is routed correctly and prop-

erly adjusted.

Choke Cable Lubrication and Inspection

• Whenever the cable is removed, or in accordance with

the Periodic Maintenance Chart, lubricate the choke cable

(see General Lubrication in the Appendix chapter).

○Apply a thin coating of grease to the cable lower end.

○Use a commercially available pressure cable lubricator to

lubricate the cable.

○With the cable disconnected at both ends, the cable

should move freely in the cable housing.

3-16 FUEL SYSTEM

Carburetors

Idle Speed Inspection

• Refer to Idle Speed Inspection in the Periodic Mainte-

nance chapter (see Idle Speed Inspection in the Periodic

Maintenance chapter).

Idle Speed Adjustment

• Refer to Idle Speed Adjustment in the Periodic Mainte-

nance chapter (see Idle Speed Adjustment in the Periodic

Maintenance chapter).

Engine Vacuum Synchronization Inspection

• Refer to Engine Vacuum Synchronization Inspection in

the Periodic Maintenance chapter (see Engine Vacuum

Synchronization Inspection in the Periodic Maintenance

chapter).

Engine Vacuum Synchronization Adjustment

• Refer to Engine Vacuum Synchronization Inspection in

the Periodic Maintenance chapter (see Engine Vacuum

Synchronization Inspection in the Periodic Maintenance

chapter).

Pilot Screw Adjustment

If the engine idle is still not stable, adjust the pilot screw to

obtain the proper idle speed using the pilot screw adjuster

[A].

Special Tool - Pilot Screw Adjuster: 57001-1239

○Turn in the pilot screw fully but not tightly, and then back

it out the specified turns. To set the screw to its original

position.

Pilot Screw Setting:

#L: 2 1/2

#R: 1 3/4

NOTE

○The standard number of turns the pilot screw must be

backed out varies by carburetor. The values given in the

specifications should be used only when the number of

the original back out turns is unavailable.

FUEL SYSTEM 3-17

Carburetors

Service Fuel Level Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

• Situate the motorcycle so that it is perpendicular to the

ground.

• Remove:

Front Seat (see Front Seat Removal in the Frame chap-

ter)

Fuel Tank (see Fuel Tank Removal)

• Prepare an auxiliary fuel tank and connect the fuel hose

to the carburetor.

• Prepare a fuel hose.

• Connect the fuel level gauge [A] to the carburetor float

bowl with the fuel hose.

Special Tool - Fuel Level Gauge: 57001-1017

• Hold the gauge vertically against the side of the carburetor

body so that the “middle” line [B] is several millimeters

higher than the mating surface [C] of the carburetor float

bowl.

• Feed fuel to the carburetor, then turn the carburetor drain

plug out a few turns.

• Wait until the fuel level in the gauge settles.

3-18 FUEL SYSTEM

Carburetors

• Keeping the gauge vertical, align the “middle” line with the

mating surface.

NOTE

○Do not lower the “middle” line below the mating surface

of the carburetor float bowl. If the gauge is lowered

and then raised again, the fuel level measured shows

somewhat higher than the actual fuel level. If the gauge

is lowered too far, dump the fuel out of it into a suitable

container and start the procedure over again.

• Read the fuel level [E] in the gauge and compare to the

specification.

• Screw in the carburetor drain plug [D].

• Stop feeding and remove the fuel level gauge.

If the fuel level is incorrect, adjust it (see Service Fuel

Level Adjustment).

Service Fuel Level (above the mating surface of carburetor

float bowl)

Standard:

0.5 mm ±1 mm (0.02 ±0.04 in.)

Service Fuel Level Adjustment

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

• Remove the carburetor, and drain the fuel into a suitable

container.

• Remove the fittings with water hose.

• Remove the float bowl.

• Slide out the pivot pin [A] with a suitable tool [B], and

remove the float [C] and float valve needle [D].

FUEL SYSTEM 3-19

Carburetors

• Bend the tang [A] on the float arm very slightly to change

the float height. Increasing the float height lowers the fuel

level and decreasing the float height raises the fuel level.

Float height

Standard:

17 ±2 mm (0.67 ±0.08 in.)

NOTE

○Do not push the needle rod [A] in during the float height

measurement [B].

• Assemble the carburetor, and recheck the fuel level.

If the fuel level cannot be adjusted by this method, the

float or the float valve [C] is damaged.

Fuel System Cleanliness Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

• Remove:

Right Lower Fairing (see Lower Fairing Removal in the

Frame chapter)

• Connect a suitable hose [A] to the fitting at the bottom of

each carburetor float bowl.

• Run the lower end of the carburetor drain hose into a suit-

able container.

• Turn out each drain plug [B] a few turns and drain the float

bowls with a hexagon wrench [C].

• Check to see if water or dirt comes out.

• Tighten the drain plug.

If any water or dirt appears during the above inspection,

clean the fuel system (see Carburetor Cleaning and Fuel

Tank Cleaning).

3-20 FUEL SYSTEM

Carburetors

Carburetor Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

• Remove:

Front Seat (see Front Seat Removal in the Frame chap-

ter)

Fuel Tank (see Fuel Tank Removal)

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Battery (see Battery Removal in the Electrical System

chapter)

Battery Damper

Battery Case Screws [A]

Battery Case [B]

• Remove the air cleaner housing mounting bolts [A].

• Loosen the carburetor holder clamps [B] off the air cleaner

ducts.

• Pull the air cleaner housing rearward.

• Remove the throttle cable and choke cable (see Throttle

Cable and Choke Cable Removal)

• Remove:

Bolts [C]

Bracket [D]

Carburetor [E]

• Stuff the pieces of lint-free, clean cloths into the carbure-

tor holder and the air cleaner duct to keep dirt out of the

engine and air cleaner.

WARNING

If dirt or dust is allowed to pass through into the

carburetor, the throttle may become stuck, possibly

causing accident. Replace the air cleaner element

according to the maintenance chart.

NOTICE

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

FUEL SYSTEM 3-21

Carburetors

Carburetor Installation

• Route the cables, harness, and hoses correctly (see Ca-

ble, Wire and Hose Routing section in the Appendix chap-

ter).

• Tighten the clamps for the carburetor holders and slide

back the spring bands for the air cleaner housing securely.

• Check fuel leakage from the carburetor.

WARNING

Fuel spilled from the carburetor is hazardous.

• Adjust the following items if necessary.

Idle Speed (see Idle Speed Adjustment in the Periodic

Maintenance chapter)

Carburetor Synchronization (see Carburetor Synchro-

nization Adjustment in the Periodic Maintenance chap-

ter)

Throttle Cable (see Throttle Control System Inspection

in the Periodic Maintenance chapter)

Choke Cable

Carburetor Separation

• Remove the carburetor (see Carburetor Removal).

• Pull out the air cut valve hoses [A], [B], [C] of the air cut

valve.

• Remove the choke plunger lever [D], spring [E] and car-

buretor mounting plates [F], [G].

• Gently, separately the carburetors each other.

Carburetor Joining

• When installing the carburetor, check to see that the O

-rings [A] are in place.

3-22 FUEL SYSTEM

Carburetors

• Install the fitting [A] and spring [B] as shown.

• Install the connecting plates [A] [B] and spring [C] as

shown.

• The center lines of the carburetor bores must be parallel

both horizontally and vertically. If they are not, loosen

the mounting screws and align the carburetors on a flat

surface. Retighten the mounting screws.

• After installing the choke mechanism, check to see that

the choke plunger lever slides right to left smoothly with-

out abnormal friction.

NOTICE

Fuel mixture trouble could result if the choke

plunger does not seat properly in its rest position

after the choke lever is returned.

• Visually synchronize the throttle (butterfly) valves.

○Check to see that all throttle valves open and close

smoothly without binding when turning the pulley.

○Visually check the clearance [A] between the throttle

valve and the carburetor bore in each carburetor.

If there is a difference between two carburetors, turn the

balance adjusting screw [B] to obtain the same clearance.

• Install the carburetors (see Carburetor Installation).

• Adjust the synchronization (see Carburetor Synchroniza-

tion Adjustment in the Periodic Maintenance Chapter).

FUEL SYSTEM 3-23

Carburetors

Carburetor Disassembly

• Remove the carburetors (see Carburetor Removal).

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

• For the Canada model, remove the pilot screw plug as

follows: punch a hole in the plug and pry there with an

awl or other suitable tool.

• Turn in the pilot screw and count the number of turns until

it seats fully but not tightly, and then remove the screw.

This is to set the screw to its original position when as-

sembling.

NOTICE

During carburetor disassembly, be careful not to

damage the diaphragm. Never use a sharp edge to

remove the diaphragm.

• Remove:

Spring [A]

Spring Seat [B]

Jet Needle [C]

Vacuum Piston [D]

Needle Jet [E]

Needle Jet Holder [F] and Main Jet [G]

Pilot Screw [H]

Carburetor Assembly

• Turn in the pilot screw [A] fully but not tightly, and then

back it out the same number of turns counted during dis-

assembly.

• Install the pilot screw plug as follows: install a new plug [B]

in the pilot screw hole of the carburetor body, and apply a

small amount of a bonding agent [C] to the circumference

of the plug to fix the plug.

NOTICE

Do not apply too much bonding agent to the plug or

the pilot screw itself may be fixed.

3-24 FUEL SYSTEM

Carburetors

• To install the needle jet [A], turn the carburetor body up

-side down, and drop the needle jet into place so that the

smaller diameter end [B] of the jet goes in first.

• Carefully screw in the needle jet holder [A]. It will seat

against the needle jet, pushing the end of the jet into the

carburetor bore.

Main Jet [B]

NOTICE

Do not apply force to the jet or overtighten it, as

this could damage the jet or the carburetor body,

requiring replacement.

• Install the float bowl.

• Slip the jet needle [B] through the hole in the center of

the vacuum piston, and put the spring seat [C] on the top

of the needle. Turn the seat so that it does not block the

hole at the bottom of the vacuum piston [A].

Spring [D]

• Install the carburetor top cover.

• Turn in the pilot screw fully but not tightly, and then back it

out the same number of turns counted during disassem-

bly.

• When removing the air cut valve assembly, unscrew the

mounting screws [B] and remove the cover [C], spring [D],

O-ring [E] and diaphragm [F].

• Install:

Left Carburetor [A]

Air Cut Valve Body [G]

Air Cut Valve Mounting Plate [H]

Carburetor Cleaning

WARNING

Gasoline and low-flash point solvents can be

flammable and/or explosive and cause severe

burns. Clean the carburetor in a well ventilated

area, and take care that there are no sparks or flame

anywhere near the working area; this includes any

appliance with a pilot light. Do not use gasoline or

a low-flash point solvent to clean the carburetor.

FUEL SYSTEM 3-25

Carburetors

NOTICE

Do not use compressed air on an assembled carbu-

retor, or the floats may be crushed by the pressure,

and the vacuum piston diaphragm may be dam-

aged. Remove as many rubber or plastic parts

from the carburetor as possible before cleaning the

carburetor with a cleaning solution. This will pre-

vent damage to or deterioration of the parts. The

carburetor body has plastic parts that cannot be

removed. Do not use a strong carburetor cleaning

solution which could attack these parts; instead,

use a mild high-flash point cleaning solution safe

for plastic parts. Do not use wire or any other hard

instrument to clean carburetor parts, especially

jets, as they may be damaged.

• Disassemble the carburetor (see Carburetor Disassem-

bly).

• Immerse all the metal parts in a carburetor cleaning solu-

tion.

• Rinse the parts in water.

• When the parts are clean, dry them with compressed air.

• Blow through the air and fuel passages with compressed

air.

• Assemble the carburetor (see Carburetor Assembly).

Carburetor Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

• Remove the carburetors (see Carburetor Removal).

• Before disassembling the carburetors, check the fuel level

(see Fuel Level Inspection).

If the fuel level is incorrect, inspect the rest of the carbu-

retor before correcting it.

• Slide the choke plunger lever [A] right to the left to check

that the choke plungers move smoothly.

If the choke plungers do not work properly, replace the

carburetors.

• Turn the throttle cable pulley to check that the throttle but-

terfly valves [B] move smoothly and return by spring ten-

sion.

If the throttle valves do not move smoothly, replace the

carburetors.

3-26 FUEL SYSTEM

Carburetors

• Disassemble the carburetors (see Carburetor Disassem-

bly).

• Clean the carburetors (see Carburetor Cleaning).

• Check that the O-rings on the float bowl and pilot screw

and the diaphragm on the vacuum piston are in good con-

dition.

If any of the O-rings or diaphragms are not in good con-

dition, replace them.

• Check the O-ring and diaphragm of coasting enricher sys-

tem.

If any of the O-ring or diaphragm are not in good condition,

replace them.

• Check the plastic tip [A] of the float valve needle [B]. It

should be smooth, without any grooves, scratches, or

tears.

If the plastic tip is damaged [C], replace the needle.

• Push the rod [D] in the other end of the float valve needle,

and then release it [E].

If the rod does not spring out, replace the needle.

• Check the tapered portion [A] of the pilot screw [B] for

wear or damage.

If the pilot screw is worn or damaged on the tapered por-

tion, it will prevent the engine from idling smoothly. Re-

place it.

• Check that the vacuum piston [A] moves smoothly in the

carburetor body. The surface of the piston must not be

excessively worn.

If the vacuum piston does not move smoothly, or if it is

very loose in carburetor body, replace the carburetor.

FUEL SYSTEM 3-27

Air Cleaner

Air Cleaner Element Removal

• Refer to Air Cleaner Cleaning in the Periodic Maintenance

chapter (see Air Cleaner Cleaning in the Periodic Mainte-

nance chapter).

Air Cleaner Element Installation

• Refer to Air Cleaner Cleaning in the Periodic Maintenance

chapter (see Air Cleaner Cleaning in the Periodic Mainte-

nance chapter).

Air Cleaner Housing Removal

• Remove:

Front Seat (see Front Seat Removal in the Frame chap-

ter)

Rear Seat (see Rear Seat Removal in the Frame chap-

ter)

Fuel Tank (see Fuel Tank Removal)

Rear Fender (see Rear Fender Removal in the Frame

chapter)

• Pull out the rear axle and place the rear wheel [A] on the

ground.

• Take out the bolts [A] and remove the fuel tank bracket

[B].

• Pull out the starter relay [C].

• Remove the rear brake reservoir bolt [A] and disconnect

the clamp [B], and free the rear brake reservoir and main

harness from the frame.

• Remove the air cleaner cap [C].

• Remove:

Carburetor Holder Clamps [A] (Loosen)

Air Cleaner Housing Mounting Bolts [B]

Air Suction Valve Hose [C]

• Remove the air cleaner housing [D], pulling out the duct

portion [E] from the grommet.

3-28 FUEL SYSTEM

Air Cleaner

• Cover the carburetors intakes with a clean, lint-free towel

to keep dirt or other foreign material from entering.

WARNING

If dirt or dust is allowed to pass through into the car-

buretors, the butterfly valves may become stuck,

possibly causing accident. Replace the air cleaner

element according to the maintenance chart.

NOTICE

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

Air Cleaner Housing Installation

• Install the air cleaner housing clamps [A] as shown.

Approx. 18° [B]

Air Cleaner Housing Disassembly

• Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)

Air Cleaner Element (see Air Element Removal in the

Periodic Maintenance chapter)

Screw [A]

Right Cover [B]

Flame Arrester

Air Cleaner Housing Assembly

• Install the flame arrester [A].

• Be sure the O-ring [B] is in position.

Kawasaki Ninja 250R Motorcycle. Service Manual (2007) - page 1