Positioning:
The Kawasaki KSF250 Mojave was positioned as a capable and versatile sport ATV, offering a blend of performance and reliability for recreational riders and casual off-road enthusiasts. It competed in a segment with other popular 250cc class ATVs.
Competitors:
Key competitors in the mid-size sport ATV market during this era included models from Yamaha (e.g., Warrior 350), Suzuki (e.g., QuadSport 250), and Honda (e.g., Sportrax 250).
Design Philosophy:
Designed for agility, ease of use, and reliable off-road performance with a focus on user-friendliness for its target demographic.
Value Proposition:
This factory service manual offers unparalleled accuracy and detail, ensuring that owners and technicians can maintain and repair the KSF250 Mojave to factory specifications, preserving its performance and longevity.
Engine Details:
Complete disassembly, assembly, inspection, and repair of all engine components including cylinder head, piston, crankshaft, camshaft, valves, lubrication system, cooling system, and more.
Fuel And Carburetion:
Detailed carburetor service, jetting information, fuel tank, fuel pump (if applicable), and fuel lines.
Ignition And Electrical:
CDI system, spark plug diagnosis, stator, regulator/rectifier, battery maintenance, wiring diagrams, lighting system, and starter system.
Transmission And Drivetrain:
Clutch operation, gear shifting mechanisms, chain drive maintenance, lubrication, and internal transmission component service.
Suspension And Steering:
Front fork service (oil changes, seal replacement, damping adjustments), rear shock absorber service, swingarm, steering head bearing maintenance, and wheel bearing service.
Braking System:
Front and rear brake caliper service, master cylinder service, brake fluid replacement, bleeding procedures, brake pad inspection and replacement, and brake hose inspection.
Frame And Body:
Frame inspection, handlebar replacement, seat removal, fender and plastic component service, and chassis lubrication points.
Routine Maintenance:
Oil changes, filter replacements, air filter cleaning, spark plug replacement, chain adjustment, brake inspection, tire pressure checks.
Repair And Rebuild:
Engine rebuilds, carburetor overhauls, clutch replacement, suspension component overhauls, brake caliper rebuilds, electrical component troubleshooting and replacement.
Diagnostics And Troubleshooting:
Step-by-step guides for identifying and resolving common mechanical and electrical issues, including symptom-based troubleshooting charts.
Specifications And Torques:
Detailed torque specifications for all critical fasteners, valve clearances, compression test specifications, and other essential service data.
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission overhauls. Suitable for both DIY enthusiasts and professional mechanics.
Engine Type:
Four-stroke, SOHC, air-cooled
Bore X Stroke:
71.0 x 64.4 mm
Valve Clearance Intake:
0.04-0.08 mm (cold)
Valve Clearance Exhaust:
0.05-0.09 mm (cold)
Horsepower:
Approx. 22 HP (estimated, varies by market and tuning)
Torque:
Approx. 19 Nm (estimated, varies by market and tuning)
Fuel Delivery:
Carburetor
Carburetor Model:
Keihin CVK32
Fuel Type:
Unleaded gasoline, Octane rating 87 or higher
Fuel Tank Capacity:
10.5 Liters (2.77 US gal)
Safety Standards:
Manufactured to meet relevant ATV safety standards of its time. Specific crash test ratings not typically published for ATVs in this class.
Braking System:
Hydraulic disc brakes front and rear, offering reliable stopping power.
Suspension Design:
Long-travel suspension for improved handling and stability over varied terrain.
Body Protection:
Full floorboards and fenders for rider protection from debris and terrain.
Lighting:
Dual headlights and a taillight for visibility.
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 3,000 km (1,800 miles) or 12 months.
Air Filter Cleaning:
Every 500 km (300 miles) or after riding in dusty conditions.
Spark Plug Check:
Every 1,000 km (600 miles).
Chain Lubrication Adjustment:
Every 500 km (300 miles) and check for slack.
Brake Fluid Replacement:
Every 2 years.
Engine Oil Type:
SAE 10W-40, API SG or higher (e.g., Kawasaki Genuine Motorcycle Oil)
Engine Oil Capacity:
1.7 Liters (1.8 US qt) without filter change; 1.9 Liters (2.0 US qt) with filter change.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Coolant Type:
Air-cooled engine, no coolant specified.
Carburetor Performance:
Carburetors can sometimes become clogged with age and fuel deposits, affecting idle and performance. Regular cleaning and proper fuel storage are recommended.
Suspension Wear:
Like many ATVs of this era, suspension bushings and seals can wear over time, leading to play and reduced damping. The manual details procedures for inspection and replacement.
Electrical Connections:
Corrosion or loose connections in the electrical system can cause intermittent issues. The manual's wiring diagrams are crucial for diagnosis.
Kawasaki Atv Legacy:
Kawasaki has a long history in powersports, including a significant presence in the ATV market with iconic models. The Mojave line was part of their expansion into sport and utility ATVs.
Mojave Development:
The KSF250 Mojave was introduced as a competitor in the sport ATV segment, offering a balance of performance and affordability. Subsequent revisions focused on refining suspension, ergonomics, and engine tuning.
Production Years:
The Kawasaki Mojave 250 was produced for a significant period, with the 2002 model year representing a mature iteration of the design.
Manufacturing Location:
Kawasaki vehicles are typically manufactured in Japan or at their international production facilities.
