Kawasaki KSF 250 Mojave Service Repair Manual 1987-2004

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类型: Atv

斯库: 135334

标签: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 ATV Kawasaki KSF 250 Mojave Mojave Models Powersports

产品多属性

Description

Welcome to the comprehensive service manual for the Kawasaki KSF250 Mojave, a distinguished All-Terrain Vehicle (ATV) produced from 1987 to 2004. Renowned for its robust 4-stroke, air-cooled 249 cc engine and user-friendly semi-automatic 5-speed transmission, the KSF250 Mojave offered a balanced blend of performance and reliability for sport ATV enthusiasts. Its enduring design, characterized by a capable chassis, effective suspension, and dual hydraulic disc front brakes with a single rear disc, made it a popular choice for recreational riding. This manual covers all KSF250 Mojave variants throughout its production years, providing in-depth technical information derived from workshop-level documentation. This service manual serves as an essential resource for maintaining and repairing your Kawasaki KSF250 Mojave. It provides detailed, step-by-step instructions and clear diagrams covering all major systems, including engine assembly and overhaul, fuel and ignition systems, transmission and drivetrain, suspension, steering, braking, and electrical components. The manual also outlines routine maintenance schedules, diagnostic procedures for common issues, and specific fluid and part recommendations. Whether you are a professional technician or a dedicated DIY enthusiast, this guide is designed to empower you with the knowledge needed to ensure your ATV remains in optimal condition, offering significant cost savings and promoting safe operation.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KSF 250 Mojave

Model Code:

KSF250

Year Range:

1987-2004

Codes

Vin Code Region:

👋 Introduction

Market Position

Product Category:

Powersports Service Manual

Target Market:

Owner-operators of Kawasaki KSF 250 Mojave ATVs, independent repair shops.

Competitive Analysis

Manual Quality:

Represents official workshop-level documentation, offering a high degree of accuracy and detail.

Key Features

Key Selling Points:

Comprehensive coverage, detailed diagrams, step-by-step instructions, cost savings on repairs, empowers DIY maintenance.

📋 Manual Details

Coverage Areas

Model Years Covered:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004

Vehicle Type:

ATV (All-Terrain Vehicle)

Variant Coverage:

All KSF250 Mojave variants

Page Count

Estimated Page Count:

Extremely detailed (exact count not specified, but comprehensive)

Manual Type

Manual Type:

Service/Workshop Manual

Intended Audience:

Professional Technicians and DIY Enthusiasts

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine assembly, disassembly, overhaul, lubrication, cooling system, fuel system (carburetor specific), ignition system, starting system, exhaust system.

Transmission Drivetrain:

Clutch, gearbox, final drive, drive chain maintenance.

Suspension Steering:

Front suspension (including shocks and A-arms), rear suspension (swingarm, shock), steering system, wheel bearings.

Braking System:

Front and rear brake system servicing (hydraulic), brake fluid, caliper maintenance, rotor inspection.

Wheels Tires:

Wheel mounting, tire pressure, wheel bearing maintenance.

Electrical System:

Wiring diagrams, lighting, charging system (stator, rectifier/regulator), battery, ignition system troubleshooting, electrical component testing.

Bodywork Frame:

Frame inspection, body panel removal and installation, seating, fenders, controls.

Procedures Included

Maintenance Procedures:

Routine maintenance (oil changes, filter replacements, spark plug replacement), pre-ride inspections, seasonal storage procedures.

Repair Procedures:

Engine rebuilds, transmission overhauls, carburetor tuning and rebuilding, suspension component replacement, brake system repairs, electrical system troubleshooting and repair.

Diagnostic Procedures:

Troubleshooting guides for common issues, diagnostic steps for electrical and mechanical problems.

Technical Depth

Depth Of Coverage:

Comprehensive: from basic maintenance to complete engine and transmission rebuilds.

Diagrams Illustrations:

Detailed step-by-step diagrams, exploded views, wiring diagrams, schematic illustrations.

Special Tools:

References to specialized tools required for certain procedures.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Likely searchable within PDF, depending on original scan quality.

Print Quality

Printability:

All pages are printable.

Binding Type

Binding Type:

Digital (PDF - no physical binding)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve

Displacement:

249 cc (15.2 cu in)

Bore X Stroke:

71.0 x 61.2 mm (2.80 x 2.41 in)

Cooling System:

Air-cooled

Performance

Horsepower Estimate:

Approx. 18-20 HP (varies by specific year and tuning)

Fuel System

Fuel Delivery:

Carburetor (e.g., Mikuni VM26SS for many models)

Recommended Fuel:

Unleaded gasoline, 87 octane minimum

Lubrication

Oil Type:

API SE, SF, or SG classification, SAE 10W-40 motorcycle oil recommended (refer to manual for precise spec)

Oil Capacity:

Approx. 1.8 L (1.9 US qt) with filter change (refer to manual for precise spec)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, semi-automatic (clutch lever not required for shifting)

Clutch Type:

Wet, multi-disc

Features

Drive System:

2WD (Rear Wheel Drive)

Final Drive:

O-ring sealed chain

Transmission Oil Type:

API GL-4, SAE 80W-90 gear oil (refer to manual for precise spec)

📐 Dimensions

Exterior

Overall Length:

Approx. 1820 mm (71.7 in) (varies slightly by year)

Overall Width:

Approx. 1130 mm (44.5 in) (varies slightly by year)

Overall Height:

Approx. 1090 mm (42.9 in) (varies slightly by year)

Weights

Dry Weight:

Approx. 170 kg (375 lbs) (varies slightly by year)

Fuel Capacity:

Approx. 10 L (2.6 US gal)

Wheels

Front Tire Size:

AT22x7-10 (example, refer to manual for specific year)

Rear Tire Size:

AT22x10-10 (example, refer to manual for specific year)

Wheel Bolt Pattern:

4x110 mm (typical for Kawasaki ATVs of this era)

🛡️ Safety Features

Ratings

Atv Classification:

Sport ATV

Active Features

Braking System Type:

Front: Dual Hydraulic Disc; Rear: Single Hydraulic Disc

Passive Features

Lighting:

Headlights, Taillight/Brake Light

💡 Technology Features

Infotainment

Instrumentation:

Basic digital or analog instrumentation including speedometer, odometer, neutral indicator, and possibly high-beam indicator.

Driver Assistance

Atv Specific Features:

Semi-automatic transmission simplifies operation compared to manual clutch systems.

Connectivity

Charging System:

Stator and rectifier/regulator for charging the 12V battery, powering lights and ignition.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1,000 km (600 miles) or annually (refer to manual for exact recommendation based on usage)

Air Filter Cleaning:

Every 500 km (300 miles) or more frequently in dusty conditions (refer to manual)

Spark Plug Replacement:

Every 3,000 km (1,800 miles) or as needed (refer to manual for specific plug type and gap)

Chain Lubrication Adjustment:

Every 500 km (300 miles) or after washing/rain (refer to manual for proper tension)

Fluid Specifications

Engine Oil Specification:

SAE 10W-40, API SE/SF/SG (check manual for latest recommendations)

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid (check manual for exact specification)

Transmission Gear Oil:

SAE 80W-90 API GL-4 (check manual for exact specification)

Known Issues

Common Wear Items:

Brake pads, wheel bearings, chain and sprockets, carburetor components (especially jets and seals), swingarm bushings.

Potential Issues Over Time:

Carburetor gumming if not stored properly, electrical connections becoming corroded, suspension seals degrading.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Model Evolution

Model Introduction:

The KSF250 Mojave was a popular sport ATV known for its reliable engine and capable chassis.

Key Updates Over Years:

While the core design remained consistent, minor updates in suspension tuning, braking, and aesthetics occurred throughout its production run. This manual covers the extensive 1987-2004 period.

Production

Production Location:

Likely manufactured in Japan or at Kawasaki's North American facilities.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The KSF250 Mojave was well-regarded in its segment for its durability and performance during its production run.

Ratings

Reliability Reputation:

Generally considered a reliable and robust ATV with proper maintenance.