Kawasaki KSF250 Mojave 1999 Factory Service Repair Manual

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Mots clés: 1999 ATV Kawasaki KSF250 Mojave Mojave Models Powersports

Variantes de produits

Description

The 1999 Kawasaki KSF250 Mojave is a robust Sport ATV designed for recreational trail riding and light utility tasks. Building on Kawasaki's legacy of reliable powersports vehicles, this model features an air-cooled, 249cc four-stroke engine paired with a 5-speed manual transmission including reverse, and a dependable 2WD chain drive system. Its capable chassis is equipped with adjustable telescopic front forks and a monoshock rear suspension, providing a comfortable and controlled ride. The Mojave was recognized as a durable and competent machine within its segment, offering a solid platform for both experienced riders and those new to ATVs. This service repair manual provides comprehensive guidance for the repair and maintenance of the 1999 Kawasaki KSF250 Mojave. It covers all essential aspects of the vehicle, including detailed procedures for engine overhaul, fuel system servicing, ignition system checks, drivetrain maintenance, suspension adjustments, braking system repairs, and electrical system troubleshooting. The manual is structured to assist mechanics and DIY enthusiasts alike, offering step-by-step instructions, diagnostic charts for common issues, and technical specifications necessary for accurate servicing and component replacement. Its purpose is to ensure the longevity and optimal performance of your KSF250 Mojave.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KSF250 Mojave

Year:

Product Type:

Factory Service Repair Manual

👋 Introduction

Market Position

Segment:

Sport ATV (All-Terrain Vehicle)

Purpose:

Designed for recreational trail riding, utility tasks, and light sport applications.

Competitive Analysis

Key Competitors:

Yamaha Warrior 350, Suzuki LT250R, Honda TRX250R (though the Mojave was generally positioned slightly below the high-performance racing models).

Key Features

Engine Type:

Air-cooled, four-stroke, single-cylinder engine.

Transmission:

5-speed manual transmission with reverse.

Suspension Front:

Adjustable telescopic front forks.

Suspension Rear:

Adjustable single shock absorber with linkage (Monoshock).

Drive Type:

Chain drive, 2WD.

Manual Purpose

Utility:

To provide detailed, accurate, and actionable information for servicing and repairing the 1999 Kawasaki KSF250 Mojave.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, maintenance, and adjustments for Kawasaki KSF250 Mojave 1999

Target Audience:

Mechanics and DIY persons

Page Count

Estimated Pages:

Likely between 300-500 pages (typical for factory service manuals of this era and type)

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Format:

Digital (PDF) or Printed (based on sales offering)

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the engine components

Fuel System:

Carburetor tuning, cleaning, and component replacement

Ignition System:

Ignition timing, spark plug specifications, CDI unit testing

Drivetrain:

Transmission disassembly, inspection, and repair; clutch operation and adjustment

Suspension:

Front fork (telescopic) overhaul, rear shock absorber maintenance, linkage adjustment

Braking System:

Hydraulic brake system inspection, bleeding, pad replacement, caliper maintenance

Electrical System:

Wiring diagrams, lighting system, battery maintenance, charging system testing

Chassis Frame:

Frame inspection, steering head bearing service, swingarm maintenance

Bodywork:

Plastic body panel removal, installation, and care

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning

Troubleshooting:

Diagnostic charts for common problems and their solutions

Major Repairs:

Engine rebuilds, transmission overhauls, suspension rebuilds

Component Replacement:

Step-by-step guides for replacing parts like carburetors, starters, batteries, brake calipers

Adjustment Procedures:

Carburetor synchronization, clutch adjustment, brake lever free play adjustment

Technical Depth

Depth:

Comprehensive, covering everything from basic checks to full engine and transmission rebuilds, including torque specifications and specialized tool requirements.

📊 Manual Specifications

File Format

Digital Format:

PDF (typically searchable and printable)

Print Quality

Print Quality:

High resolution images and clear text, suitable for printing detailed diagrams

Binding Type

Binding Type:

N/A (for digital format); Typically perfect bound or spiral bound for printed versions.

Paper Type

Paper Type:

N/A (for digital format); Typically heavy-duty, glossy paper for printed versions to withstand workshop use.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve, single-cylinder

Displacement:

249 cc (15.2 cu. in.)

Bore X Stroke:

72.0 x 61.2 mm (2.83 x 2.41 in)

Cooling System:

Air-cooled

Compression Ratio:

9.7:1

Starting System:

Electric starter

Performance

Horsepower Est:

Approximately 20-25 HP (at crankshaft, depending on tuning)

Torque Est:

Not officially published, but estimated to be around 15-18 lb-ft

Fuel System

Carburetor:

Keihin CVK34 (single carburetor)

Fuel Capacity:

2.6 gal (9.8 L)

Ignition

Ignition:

Digital CDI (Capacitor Discharge Ignition)

Lubrication

Oil Capacity:

1.8 L (1.9 US qt) with filter change

Recommended Oil:

SAE 10W-40 API SG or higher (specifics in manual)

🔧 Transmission

Standard

Type:

5-speed manual with reverse

Clutch:

Wet, multi-disc, manual clutch

Optional

Optional Features:

Features

Drive:

O-ring sealed chain, 2WD

Transmission Oil Capacity:

0.5 L (0.5 US qt) (engine oil serves transmission)

📐 Dimensions

Exterior

Overall Length:

1,835 mm (72.2 in)

Overall Width:

1,130 mm (44.5 in)

Overall Height:

1,100 mm (43.3 in)

Wheelbase:

1,215 mm (47.8 in)

Ground Clearance:

115 mm (4.5 in)

Weights

Dry Weight:

164 kg (361.6 lbs)

Curb Weight:

Not specified, but typically around 175-180 kg including fluids.

Cargo

Cargo Capacity:

Front and rear racks for light cargo carrying.

🛡️ Safety Features

Ratings

Atv Safety:

As with all ATVs, operator safety is paramount. This manual focuses on mechanical safety, not user-provided safety gear or riding practices.

Active Features

Braking Type:

Hydraulic disc brakes front and rear.

Parking Brake:

Mechanical parking brake lever acting on rear brake.

Passive Features

Frame Construction:

Steel tube frame for durability.

Lighting:

Headlight, taillight, and brake light for visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a 1999 ATV, no modern infotainment features).

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Options:

Engine Management

Ignition Type:

Electronic CDI ignition provides reliable spark delivery.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1,000 km (600 miles) or 6 months, whichever comes first. Initial break-in service at 100 km (60 miles).

Air Filter Cleaning:

Every 500 km (300 miles) or if conditions are dusty.

Spark Plug Check:

Every 1,000 km (600 miles).

Chain Lubrication Adjustment:

Every 500 km (300 miles) or after washing/wet riding.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher.

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for exact specification).

Coolant:

N/A (air-cooled engine).

Known Issues

Carburetor Fouling:

Common with infrequent use or poor fuel quality, requires cleaning and proper jetting.

Suspension Seals:

Wear and tear on fork seals can lead to leaks, requiring replacement.

Rear Axle Bearings:

Can wear over time, leading to play and potential damage if not addressed.

Maintenance Tools

Special Tools:

The manual will list specific tools required for complex procedures, such as flywheel pullers, clutch compressors, and torque wrenches.

📚 Vehicle History

Brand Heritage

Kawasaki Atv:

Kawasaki has a long history in powersports, including a significant period of ATV production, known for robust engineering and reliable engines.

Model Evolution

Mojave Lineage:

The KSF250 Mojave was introduced in the late 1980s as a mid-range sport/utility ATV. It evolved with minor updates over the years, with the 1999 model representing a mature iteration of the platform.

Production

Production Years:

1987-2004

Manufacturing Location:

Japan (Kawasaki Heavy Industries, Ltd.)

🏆 Awards & Recognition

Recognitions

Atv Awards:

Specific awards for the 1999 Mojave are not widely documented; however, it was generally well-regarded as a durable and capable recreational ATV of its era.