Vehicle Category:
Sport/Recreation ATV (All-Terrain Vehicle)
Competitors:
Suzuki LT250R, Yamaha Warrior 350, Honda TRX250R/X.
Vehicle Highlights:
Known for its reliable 250cc engine, stable chassis, and capable suspension for its era. Popular in recreational riding and desert racing.
Purpose For Owner:
Essential for maintaining peak performance, diagnosing issues, and performing repairs on the 1994 Kawasaki KSF250 Mojave, saving time and money on dealer service.
Primary Coverage:
Repair, maintenance, and adjustment procedures for the 1994 Kawasaki KSF250 Mojave.
Estimated Pages:
Unknown (typical for this era, likely 300-500 pages)
Type:
Service Repair Manual
Format:
Digital (likely PDF, potentially scanned from original print)
Engine:
Detailed disassembly, assembly, inspection, and repair of the 250cc 4-stroke engine (Kawasaki KL250-related).
Fuel System:
Carburetor (Mikuni VM32SS or similar) tuning, cleaning, and overhaul; fuel tank, lines, and petcock maintenance.
Ignition System:
CDI ignition system testing, troubleshooting, spark plug specifications, coil and stator testing.
Transmission:
Clutch operation, gearshift mechanism, transmission disassembly and reassembly, lubrication.
Drivetrain:
Chain drive maintenance, lubrication, adjustment; rear axle and sprocket inspection.
Suspension:
Front telescopic forks (including oil type and capacity), rear swingarm suspension, shock absorber service and adjustment.
Brakes:
Front and rear hydraulic disc brake system service, pad replacement, caliper overhaul, fluid specifications (DOT 3/4), bleeding procedures.
Electrical System:
Wiring diagrams, lighting system (headlight, taillight, brake light, turn signals), battery maintenance, charging system (stator and regulator/rectifier testing).
Cooling System:
Air-cooled engine, no liquid cooling system details.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fenders, handlebars, and controls.
Maintenance:
Regular maintenance checks, lubrication points, filter replacements (air, oil if applicable), valve clearance adjustment, chain tensioning.
Troubleshooting:
Systematic diagnostic flowcharts for common performance issues, starting problems, and electrical faults.
Repair:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.
Installation:
Procedures for installing new parts or components.
Specifications:
Torque specifications for all fasteners, clearances, fluid capacities, electrical resistance values.
Depth:
Comprehensive, suitable for DIY mechanics and professional technicians. Covers routine maintenance to full engine and transmission rebuilds.
Digital Format:
Likely PDF (Portable Document Format), optimized for digital viewing and printing.
Print Suitability:
Designed to be printable, with clear text and diagrams. Quality dependent on original source scanning.
Original Binding:
Original manual would have been professionally bound (e.g., saddle-stitched or perfect bound).
Original Paper:
Typically printed on high-quality, durable paper stock suitable for shop environments.
Engine Type:
249cc, 4-stroke, SOHC, 2-valve, single-cylinder, air-cooled.
Bore X Stroke:
66.0 x 72.0 mm (typical for KL250 series engine).
Compression Ratio:
9.0:1 (typical for KL250 series engine).
Horsepower:
Approximately 18-20 HP at 6500 RPM (estimated).
Torque:
Approximately 15-17 lb-ft at 5500 RPM (estimated).
Carburetor:
Mikuni VM32SS or similar, single downdraft carburetor.
Fuel Type:
Unleaded gasoline, 87 octane (minimum).
Oil Type:
API SE, SF, or SG classification, SAE 10W-40 or 20W-50 motorcycle oil.
Oil Capacity:
Approximately 1.7 L (1.8 US qt) without filter change, 1.9 L (2.0 US qt) with filter change (typical).
Transmission Type:
6-speed constant mesh, sequential manual transmission.
Clutch Type:
Wet multi-disc, manual clutch operation.
Gear Ratios:
Specific ratios detailed in the manual.
Transmission Fluid:
API GL-1 or GL-4 gear oil, SAE 80W-90 (check manual for precise spec).
Overall Length:
Approx. 1835 mm (72.2 in)
Overall Width:
Approx. 1100 mm (43.3 in)
Overall Height:
Approx. 1045 mm (41.1 in)
Wheelbase:
Approx. 1260 mm (49.6 in)
Dry Weight:
Approx. 210 kg (463 lbs)
Fuel Capacity:
Approx. 9.0 L (2.4 US gal), including reserve.
Atv Safety Considerations:
ATVs require proper protective gear (helmet, goggles, gloves, boots, long sleeves/pants) and safe riding practices. This manual focuses on mechanical safety.
Braking System:
Dual hydraulic disc brakes front, single hydraulic disc brake rear provide effective stopping power.
Chassis Design:
Steel frame and suspension components are designed for stability and rider control in off-road conditions.
Oil Change Interval:
Every 1000 km (600 miles) or 6 months, whichever comes first. Initial break-in oil change recommended much sooner.
Air Filter Cleaning:
Every 500 km (300 miles) or more frequently in dusty conditions.
Valve Clearance Check:
Every 2000 km (1200 miles) or 12 months.
Chain Maintenance:
Lubricate and adjust chain tension every 500 km (300 miles).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Engine Oil Viscosity:
SAE 10W-40 or SAE 20W-50 motorcycle specific oil recommended.
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, brake pads and rotors, carburetor jetting issues due to age/buildup.
Carburetor Problems:
Clogged jets, float bowl contamination, vacuum leaks can cause hard starting, poor idling, and bogging.
Electrical Issues:
Corroded connectors, failing regulator/rectifier, or stator can lead to charging system problems.
Kawasaki Legacy:
Kawasaki has a long history of producing reliable and performance-oriented motorcycles and powersports vehicles, including successful ATVs.
Mojave Development:
The KSF250 Mojave was Kawasaki's entry into the sport ATV market, evolving from their utility and dual-sport motorcycle engine platforms (like the KL250).
Production Years:
Produced from the late 1980s through the early 2000s, with the 1994 model representing a mid-cycle iteration.
