Vehicle Segment:
Sport ATV (All-Terrain Vehicle)
Target Audience:
Recreational riders, off-road enthusiasts, and DIY mechanics seeking to maintain or repair their Kawasaki KSF250 Mojave.
Competitors:
Yamaha Warrior 350, Suzuki LT-Z400, Honda TRX300EX/TRX400EX (at the time of its production).
Model Highlights:
The KSF250 Mojave was known for its reliable performance, balanced handling, and comfortable riding position, making it a popular choice for trail riding and recreational sport ATV use.
Benefits To Owner:
Enables owners to perform routine maintenance, diagnose issues, and execute repairs efficiently, saving time and money on professional servicing, and prolonging the vehicle's lifespan.
Systems Covered:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Lubrication System, Chassis, Bodywork, Troubleshooting, Maintenance, Specifications, Diagrams
Estimated Page Count:
Approximately 300-400 pages (typical for a comprehensive factory service manual)
Manual Type:
Factory Service Manual / Repair Manual
Format:
Print / Digital (PDF)
Engine Service:
Detailed disassembly, assembly, inspection, and repair procedures for the 249cc engine, including cylinder head, piston, crankshaft, valve train, and timing.
Transmission And Drivetrain:
Comprehensive coverage of the 5-speed transmission, clutch operation, final drive (chain and sprockets), and gearbox inspection and repair.
Suspension And Steering:
In-depth guides for front and rear suspension systems (shock absorbers, springs, control arms), wheel bearing service, and steering system (handlebar, steering stem, tie rods).
Brake System:
Detailed procedures for front and rear disc brake systems, including caliper overhaul, master cylinder service, brake pad replacement, and bleeding procedures.
Electrical System:
Complete wiring diagrams, troubleshooting guides for ignition, lighting, charging system (stator, regulator/rectifier), starter motor, battery, and fuses.
Fuel And Cooling Systems:
Carburetor (Mikuni VM34SS) disassembly, cleaning, adjustment, and troubleshooting. Radiator and fan operation, coolant specifications, and fluid replacement.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, spark plug checks, air filter cleaning, brake adjustments, and general inspection routines.
Troubleshooting:
Systematic diagnostic procedures for common problems, including starting issues, running problems, electrical faults, and braking irregularities, with symptom-based troubleshooting charts.
Major Repairs And Overhauls:
Complete guides for engine rebuilding, transmission overhauls, suspension component replacement, and complete brake system rebuilds.
Component Disassembly And Assembly:
Step-by-step instructions for removing, disassembling, cleaning, inspecting, repairing, and reassembling all major components and sub-assemblies.
Technical Specifications And Data:
Torque specifications for all fasteners, fluid capacities, tolerances, clearances, and diagnostic data required for proper repair and maintenance.
Depth Of Coverage:
Comprehensive: Covers everything from basic preventative maintenance and adjustments to full engine and transmission overhauls, including electrical diagnostics and chassis repairs.
Digital File Type:
PDF (Portable Document Format)
PDF Features:
Searchable text, high-resolution diagrams, printable pages.
Print Quality Description:
High-quality reproductions of original factory documentation, ensuring clarity of text and diagrams.
Binding Type:
Typically coil-bound or perfect-bound for ease of use and lay-flat capability (for print versions).
Paper Type:
Durable paper stock suitable for workshop environments, often with a matte finish to reduce glare.
Manual Scope:
Full factory service manual, designed for professional technicians and experienced DIYers. It provides detailed procedural information for repair and maintenance.
Engine Type:
Four-stroke, SOHC, 2-valve
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm
Cooling System:
Liquid-cooled
Ignition System:
CDI (Capacitor Discharge Ignition)
Horsepower Estimate:
Approximately 18-20 HP (Horsepower), specific figures vary slightly based on tuning and region.
Torque Estimate:
Approx. 15-17 Nm (Newton-meters), specific figures vary.
Carburetor Model:
Mikuni VM34SS
Fuel Type:
Unleaded gasoline
Oil Type Specification:
SAE 10W-40 API SG or higher (refer to manual for exact Kawasaki recommendation)
Oil Capacity With Filter:
Approximately 2.0 L (2.1 US qt)
Transmission Type:
5-speed constant mesh, return shift
Clutch Type:
Wet, multi-disc
Drivetrain:
Sealed O-ring chain, 520 pitch
Final Drive Ratio:
Typically 2.56:1 (e.g., 14T front, 36T rear sprocket)
Transmission Oil Type:
Refer to manual (typically same as engine oil, e.g., SAE 10W-40 API SG)
Length:
Approx. 1,835 mm (72.2 in)
Width:
Approx. 1,160 mm (45.7 in)
Height:
Approx. 1,070 mm (42.1 in)
Wheelbase:
Approx. 1,270 mm (50.0 in)
Dry Weight:
Approx. 210 kg (463 lbs)
Curb Weight:
Approximately 226 kg (498 lbs) (with all necessary operating fluids)
Front Tire Size:
AT22 x 7-10
Rear Tire Size:
AT22 x 10-10
Wheel Bolt Pattern Front:
4x110 mm
Wheel Bolt Pattern Rear:
4x110 mm
Safety Features Design:
Designed with rider safety in mind, incorporating stable chassis geometry, responsive braking, and durable construction for off-road use. (No formal crash test ratings like cars)
Braking System:
Dual hydraulic disc brakes (front), Single hydraulic disc brake (rear) for effective stopping power.
Suspension Stability:
Independent front suspension and a swingarm rear suspension contribute to stability and control over varied terrain.
Chassis Construction:
Robust steel frame designed for off-road durability and rider support.
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first (refer to manual for specific riding conditions).
Air Filter Cleaning:
Every 500 km (300 miles) or more frequently in dusty conditions.
Spark Plug Inspection:
Every 1,000 km (600 miles).
Chain Lubrication Adjustment:
Every 500 km (300 miles) or after washing/wet riding.
Engine Coolant:
Kawasaki Genuine Coolant or equivalent (ethylene glycol-based, 50/50 mix with distilled water recommended).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (refer to manual for specific type).
Common Wear Items:
Carburetor jets (clogging due to fuel quality), wheel bearings (due to off-road use), brake components (pads, rotors), and suspension bushings are common wear items.
Electrical Connections:
Corrosion on electrical connectors can sometimes lead to intermittent faults, especially in wet environments. The manual's troubleshooting section is crucial here.
Kawasaki Atv History:
Kawasaki has a long history in powersports, producing reliable and performance-oriented ATVs for recreational and utility purposes since the early 1980s.
Ksf250 Lineage:
The KSF250 Mojave was part of Kawasaki's sport ATV lineup, evolving from earlier models and competing in a segment that favored agility and trail performance. It was produced for many years with minor updates.
Production Period:
The KSF250 Mojave was produced for a significant period, with the 2004 model representing a mature iteration of the design. Production ceased in later years as the market shifted towards higher-performance, liquid-cooled 450cc and 700cc models.
