Kawasaki ZZR250
KAWASAKI ZZR250 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS
KAWASAKI ZZR250 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual / Repair Manual and Wiring Diagrams for motorcycles Kawasaki ZZR250. CONTENTS: General Information - Before starting to perform an inspection service or carry out a - Battery Ground - Edges of Parts - Solvent - Cleaning vehicle before disassembly - Arrangement and Cleaning of Removed Parts - Storage of Removed Parts - Inspection - Replacement Parts - Assembly Order - Tightening Sequence - Tightening Torque - Force - Gasket, O-ring - Liquid Gasket, Non-permanent Locking Agent - Press - Ball Bearing and Needle Bearing - Oil Seal, Grease Seal - Circlips, Cotter Pins - Lubrication - Direction of Engine Rotation - Electrical Wires - Instrument - Left Side View (United States and Canada) - Right Side View (United States and Canada) - Frame Number - Engine Number - Prefixes for Units: - Units of Temperature: Periodic Maintenance - The scheduled maintenance must be done in accordance with this c - Use a torque wrench to tighten bolts and nuts to their specified - Steering Stem Nut Wrench: - Fuel System - Air Cleaner Element Cleaning - Air Cleaner Element Installation - Torque - - Throttle Control System Inspection - Choke Operation Inspection - Engine Vacuum Synchronization Inspection - Special Tool - - Idle Speed Inspection - Idle Speed Adjustment - Fuel Hose Inspection (fuel leak, damage, installation condition) - Evaporative Emission Control System (California Model) - Evaporative Emission Control System Inspection - Cooling System - Coolant Level Inspection - Radiator Hose Damage and Installation Condition Inspection - Coolant Filter Cleaning (Australia Model) - Air Suction System - Air Suction System Damage Inspection - Engine Top End - Valve Clearance Inspection - Valve Clearance Adjustment - Clutch - Clutch Operation Inspection - Wheels/Tires - Air Pressure Inspection - Wheel/Tire Damage Inspection - Tire Tread Wear, Abnormal Wear Inspection - Wheel Bearing Damage Inspection - Drive Train - Drive Chain Lubrication Condition Inspection - Drive Chain Slack Inspection - Drive Chain Slack Adjustment - Wheel Alignment Inspection - Drive Chain Wear Inspection - Chain Guide Inspection - Brake System - Brake Fluid Leak (Brake Hose and Pipe) Inspection - Brake Hose and Pipe Damage and Installation Condition Inspection - Brake Operation Inspection - Brake Fluid Level Inspection - Brake Pad Wear Inspection - Brake Light Switch Operation Inspection - Suspensions - Front Forks/Rear Shock Absorber Operation Inspection - Front Fork Oil Leak Inspection - Rear Shock Absorber Oil Leak Inspection - Rocker Arm Operation Inspection - Tie-Rod Operation Inspection - Swingarm Pivot Lubrication - Steering System - Steering Play Inspection - Steering Play Adjustment - Steering Stem Bearing Lubrication - Electrical System - Lights and Switches Operation Inspection - Headlight Aiming Inspection - Sidestand Switch Operation Inspection - Engine Stop Switch Operation Inspection - Others - Chassis Parts Lubrication - Bolts, Nuts and Fasteners Tightness Inspection - Replacement Parts - Air Cleaner Element Replacement - Fuel Hose Replacement - Coolant Change - Torque - - Radiator Hose and O-ring Replacement - Engine Oil Change - Oil Filter Replacement - Brake Hose and Pipe Replacement - Brake Fluid Change - Master Cylinder Rubber Parts Replacement - Caliper Rubber Parts Replacement - Spark Plug Replacement Fuel System - Fuel Level Gauge: - Free Play Inspection - Free Play Adjustment - Throttle Cable Removal - Throttle Cable Installation - Throttle Cable Lubrication - Free Play Inspection - Free Play Adjustment - Choke Cable Removal - Choke Cable Installation - Choke Cable Lubrication and Inspection - Idle Speed Inspection - Idle Speed Adjustment - Engine Vacuum Synchronization Inspection - Engine Vacuum Synchronization Adjustment - Pilot Screw Adjustment - Special Tool - - Service Fuel Level Inspection - Special Tool - - Service Fuel Level Adjustment - Fuel System Cleanliness Inspection - Carburetor Removal - Carburetor Installation - Carburetor Separation - Carburetor Joining - Carburetor Disassembly - Carburetor Assembly - Carburetor Cleaning - Carburetor Inspection - Air Cleaner Element Removal - Air Cleaner Element Installation - Air Cleaner Housing Removal - Air Cleaner Housing Installation - Air Cleaner Housing Disassembly - Air Cleaner Housing Assembly - Oil Draining - Fuel Tank Removal - Fuel Tank Installation - Fuel Tap Removal - Fuel Tap Installation - Torque - - Fuel Tank and Tap Cleaning - Fuel Tap Inspection - Fuel Tank and Cap Inspection Cooling System - Kawasaki Bond (Silicone Sealant): - Permanent type antifreeze is used as a coolant to protect the co - Coolant Deterioration Inspection - Coolant Level Inspection - Coolant Draining - Coolant Filling - Pressure Testing - Cooling System Flushing - Pump Cover Removal - Pump Cover Installation - Torque - - Water Pump Removal - Water Pump Installation - Pump Impeller Inspection - Radiator and Radiator Fan Removal - Radiator Inspection - Radiator Cleaning - Radiator Cap Inspection - Radiator Filler Neck Inspection - Thermostat Removal - Thermostat Installation - Thermostat Housing Removal - Thermostat Housing Installation Note - Thermostat Inspection - Hose Installation - Torque - - Hose Inspection - Radiator Fan Switch, Water Temperature Switch Removal - Radiator Fan Switch, Water Temperature Switch Installation - Sealant - - Torque - - Radiator Fan Switch, Water Temperature Switch Inspection Engine Top End - Exhaust System - Compression Gauge, 20 kgf/cm : - Vacuum Switch Valve Removal - Vacuum Switch Valve Installation - Vacuum Switch Valve Operation Test - Vacuum Switch Valve Unit Test - Special Tool - - Air Suction Valve Removal - Air Suction Valve Installation - Torque - - Air Suction Valve Inspection - Clean Air System Hose Inspection - Cylinder Head Cover Removal - Cylinder Head Cover Installation - Torque - - Camshaft Chain Tensioner Removal - Camshaft Chain Tensioner Installation - Torque - - Torque - - Camshaft Removal - Camshaft Installation - Torque - - Camshaft and Sprocket Assembly - Torque - - Camshaft and Camshaft Cap Wear Inspection - Torque - - Camshaft Runout Inspection - Cam Wear Inspection - Camshaft Chain Guide Wear Inspection - Cylinder Compression Measurement - Special Tool - - Torque - - Cylinder Head Removal - Cylinder Head Installation - Torque - - Torque - - Torque - - Cylinder Head Warp Inspection - Cylinder Head Cleaning - Valve Clearance Inspection - Valve Clearance Adjustment - Valve Removal - Special Tools - - Valve Installation - Valve Guide Removal - Special Tool - - Valve Guide Installation - Special Tools - - Special Tool - - Valve-to-Guide Clearance Measurement (Wobble Method) - Valve Seat Inspection - Valve Seat Repair - Special Tools - - Seat Cutter Operation Cares - Marks Stamped on the Cutter - Operating Procedures - Cylinder Removal - Cylinder Installation - Special Tool - - Piston Removal - Special Tool - - Piston Installation - Cylinder Wear Inspection - Piston Wear Inspection - Piston Ring, Piston Ring Groove Wear Insepction - Piston Ring Groove Width Inspection - Piston Ring Thickness Inspection - Piston Ring End Gap Inspection - Boring, Honing - Carburetor Holder Installation - Muffler Removal - Muffler Installation - Exhaust System Inspection Clutch - Clutch Holder: - Clutch Lever Free Play Inspection - Clutch Lever Free Play Adjustment - Clutch Cable Removal - Clutch Cable Lubrication - Clutch Lever Removal - Clutch Cover Removal - Clutch Cover Installation Note - Special Tool - - Clutch Release Shaft Removal - Clutch Release Shaft Installation - Clutch Removal - Special Tool - - Clutch Installation - Special Tool - - Torque - - Torque - - Clutch Plate Wear and Damage Inspection - Clutch Plate Warp Inspection - Clutch Spring Free Length Inspection - Clutch Housing Finger Damage Inspection - Clutch Hub Spline Damage Inspection Engine Lubrication System - Outside Circlip Pliers: - WARNING - Oil Level Inspection - Engine Oil Change - Oil Filter Replacement - Bypass Valve Disassembly - Bypass Valve Assembly - Bypass Valve Cleaning and Inspection - Oil Screen Cleaning and Inspection - Oil Pressure Relief Valve Removal - Oil Pressure Relief Valve Installation - Torque - - Oil Pressure Relief Valve Inspection - Oil Pump Removal - Oil Pump Installation - Torque - - Oil Pump Disassembly - Special Tool - - Oil Pump Assembly - Oil Pump Inspection - Oil Pressure Measurement - Special Tools - - Oil Pressure Switch Removal - Oil Pressure Switch Installation - Sealant - - Torque - - Torque - Engine Removal/Installation - Engine Removal - Engine Installation - Torque - Crankshaft/Transmission - Bearing Puller: - Crankcase Splitting - Crankcase Assembly - Special Tool - - Special Tool - - Torque - - Torque - - Crankcase Exchange - Crankshaft Removal - Crankshaft Installation - Connecting Rod Removal - Connecting Rod Installation - Torque - - Crankshaft/Connecting Rod Cleaning - Connecting Rod Bend Inspection - Connecting Rod Twist Inspection - Connecting Rod Big End Side Clearance Inspection - Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection - Crankshaft Side Clearance Inspection - Crankshaft Runout Inspection - Crankshaft Main Bearing Insert/Journal Wear Inspection - Starter Motor Clutch Removal/Installation - Starter Motor Clutch Inspection - Starter Motor Clutch Disassembly - Starter Motor Clutch Assembly - Torque - - Balancer Removal - Balancer Installation - Balancer Shaft Bearing Insert/Journal Wear Inspection - Torque - - External Shift Mechanism Removal - External Shift Mechanism Installation - External Shift Mechanism Inspection - Torque - - Transmission Removal - Transmission Installation - Transmission Shaft Disassembly - Special Tool - - Special Tools - - Transmission Shaft Assembly - Shift Drum and Fork Removal - Shift Drum and Fork Installation - Torque - - Torque - - Shift Drum Disassembly - Shift Drum Assembly - Torque - - Gear Backlash Inspection - Shift Fork Bending Inspection - Shift Fork/Gear Groove Wear Inspection - Shift Fork Guide Pin/Drum Groove Wear Inspection - Gear Dog and Gear Dog Hole Damage Inspection - Ball and Needle Bearing Wear Inspection Wheels/Tires - Inside Circlip Pliers: - Front Wheel Removal - Front Wheel Installation - Torque - - Rear Wheel Removal - Rear Wheel Installation - Torque - - Wheel Inspection - Axle Inspection - Balance Inspection - Balance Adjustment - Balance Weight Removal - Balance Weight Installation - Air Pressure Inspection/Adjustment - Tire Inspection - Tire Removal - Special Tool - - Special Tools - - Tire Installation - Tire Repair - Hub Bearing Removal - Special Tool - - Special Tools - - Hub Bearing Installation - Special Tool - - Special Tool - - Special Tool - - Hub Bearing Inspection - Hub Bearing Lubrication - Speedometer Gear Housing Disassembly - Speedometer Gear Housing Assembly - Speedometer Gear Housing Lubrication Final Drive - Bearing Driver Set: - Drive Chain Slack Inspection - Drive Chain Slack Adjustment - Wheel Alignment Inspection/Adjustment - Drive Chain Wear Inspection - Drive Chain Lubrication - Drive Chain Removal - Drive Chain Installation - Torque - - Torque - - Drive Chain Replacement - Recommended Tool - - Engine Sprocket Removal - Engine Sprocket Installation - Torque - - Rear Sprocket Removal - Rear Sprocket Installation - Torque - - Coupling Installation - Coupling Bearing Removal - Special Tool - - Coupling Bearing Installation - Special Tool - - Special Tool - - Coupling Bearing Inspection - Coupling Bearing Lubrication - Coupling Damper Inspection - Grease Seal Inspection and Lubrication - Sprocket Wear Inspection - Rear Sprocket Warp Inspection Brakes - Inside Circlip Pliers: - Brake Pedal Position Inspection - Brake Pedal Position Adjustment - Torque - - Front Caliper Removal - Rear Caliper Removal - Caliper Installation - Torque - - Caliper Disassembly - Caliper Assembly - Caliper Fluid Seal Damage - Rear Caliper Dust Boot and Friction Boot Damage - Caliper Piston and Cylinder Damage Inspection - Caliper Holder Shaft Wear - Brake Pad Removal - Brake Pad Installation - Brake Pad Wear Inspection - Front Master Cylinder Removal - Front Master Cylinder Installation - Torque - - Rear Master Cylinder Removal - Rear Master Cylinder Installation - Torque - - Torque - - Rear Brake Reservoir Removal - Rear Brake Reservoir Installation - Front Master Cylinder Disassembly - Rear Master Cylinder Disassembly - Master Cylinder Assembly - Master Cylinder Inspection - Brake Disc Removal - Brake Disc Installation - Torque - - Brake Disc Wear Inspection - Brake Disc Warp Inspection - Brake Fluid Level Inspection - Brake Fluid Change - Brake Line Bleeding - Torque - - Torque - - Brake Hose Removal/Installation - Brake Hose Inspection Suspension - Inside Circlip Pliers: - Front Fork Removal - Front Fork Installation (each fork leg) - Torque - - Torque - - Front Fork Oil Change - Special Tool - - Front Fork Disassembly - Special Tools - - Special Tool - - Front Fork Assembly - Special Tool - - Special Tool - - Special Tools - - Torque - - Inner Tube/Outer Tube Inspection - Fork Spring Inspection - Oil Seal/Dust Seal Inspection - Spring Preload Adjustment - Special Tool - - Rear Shock Absorber Removal - Special Tools - - Rear Shock Absorber Installation - Torque - - Rear Shock Absorber Scrapping - Swingarm Removal - Special Tools - - Swingarm Installation - Torque - - Swingarm Bearing Removal - Special Tool - - Special Tool - - Swingarm Bearing Installation - Special Tool - - Swingarm Bearing, Sleeve Inspection - Swingarm Lubrication - Chain Guide Inspection - Tie-rods Removal - Special Tools - - Tie-Rod Installation - Torque - - Rocker Arm Removal - Special Tools - - Rocker Arm Installation - Torque - - Tie-rod, Rocker Arm Bushing Inspection - Tie-rod, Rocker Arm Sleeve Inspection Steering - Steering Stem Bearing Driver: - Steering Inspection - Steering Adjustment - Steering Stem, Stem Bearing Removal - Special Tool - - Special Tool - - Special Tools - - Steering Stem, Stem Bearing Installation - Special Tools - - Special Tools - - Special Tool - - Torque - - Torque - - Stem Bearing Lubrication - Grease Seal, Deterioration, Damage Inspection - Steering Stem Warp Inspection - Right Handlebar Holder Removal - Right Handlebar Holder Installation - Torque - - Left Handlebar Holder Removal - Left Handlebar Holder Installation Note - Torque - Frame - Front Seat Removal - Front Seat Installation - Rear Seat Removal - Rear Seat Installation - Lower Fairing Removal - Lower Fairing Installation - Upper Fairing Removal - Upper Fairing Installation - Upper Cover Removal - Upper Cover Installation - Side Cover Removal - Side Cover Installation - Front Fender Removal - Rear Fender Removal - Rear Fender Installation Electrical System - Flywheel Holder: - There are a number of important precautions that are musts when - Wiring Inspection - Special Tool - - Battery Removal - Battery Installation - Battery Activation - Precautions - 1) - 2) - 3) - 4) - Interchange - Charging Condition Inspection - Refreshing Charge - Alternator Cover Removal - Alternator Cover Installation - Sealant - - Torque - - Stater Coil Removal - Stator Coil Installation - Special Tool - - Torque - - Alternator Rotor Removal - Special Tool - - Special Tool - - Alternator Rotor Installation - Special Tool - - Torque - - Alternator Inspection - Special Tool - - Regulator/Rectifier Inspection - Torque - - Charging Voltage Inspection - Special Tool - - Charging System Circuit - Ignition System Troubleshooting - Crankshaft Sensor Removal - Crankshaft Sensor Installation - Special Tool - - Crankshaft Sensor Inspection - Special Tool - - Crankshaft Sensor Peak Voltage Inspection - Special Tool - - Ignition Coil Removal - Ignition Coil Installation - Ignition Coil Inspection - Special Tool - - Special Tool - - Ignition Coil Primary Peak Voltage - Special Tool - - Spark Plug Removal - Spark Plug Installation - Spark Plug Condition Inspection - IC Igniter Inspection - IC Igniter Operation Inspection - Special Tool - - Diodes Inspection - Ignition System Circuit - Starter Motor Removal - Starter Motor Installation - Starter Motor Disassembly - Starter Motor Assembly - Torque - - Torque - - Carbon Brush Inspection - Commutator Inspection, Cleaning - Armature Inspection - Special Tool - - Brush Lead Inspection - Special Tool - - Terminal Bolt Inspection - Special Tool - - Starter Relay Inspection - Special Tool - - Starter Circuit Relay Inspection - Electrical Starter Circuit - Headlight Beam Horizontal Adjustment - Headlight Beam Vertical Adjustment - Headlight Bulb Replacement - Tail/Brake Light Bulb Replacement - Front Turn Signal Light Bulb Replacement - Rear Turn Signal Light Bulb Replacement - Turn Signal Relay Inspection - Headlight Circuit Relay Inspection - Headlight/Tail Light Circuit - Turn Signal Light Circuit - WARNING - Fan System Circuit Inspection - Fan Motor Inspection - Radiator Fan Circuit - Meter Unit Removal - Meter Unit Disassembly - Meter Unit Installation - Indicator Light Replacement - Tachometer Inspection - Tachometer Circuit - Water Temperature Warning System Inspection - Water Temperature Warning System Circuit - Brake Light Timing Inspection - Brake Light Timing Adjustment - Switch Inspection - Special Tool - - Fuel Gauge Circuit - Radiator Fan Switch Inspection - Water Temperature Switch Inspection - Fuel Level Sensor Inspection - 30 A Main Fuse Removal - Fuse Removal - Fuse Installation - Fuse Inspection Appendix - California Model - California Model - Australia Model - NOTE - Engine Doesn't Start, Starting Difficulty: - Starter motor not rotating: - Starter motor rotating but engine doesn't turn over: - Engine won't turn over: - No fuel flow: - Engine flooded: - No spark; spark weak: - Compression Low: - Fuel/air mixture incorrect: - Poor Running at Low Speed: - Spark weak: - Fuel/air mixture incorrect: - Compression low: - Other: - Poor Running or No Power at High Speed: - Firing incorrect: - Fuel/air mixture incorrect: - Compression low: - Knocking: - Miscellaneous: - Overheating: - Firing incorrect: - Fuel/air mixture incorrect: - Compression high: - Engine load faulty: - Lubrication inadequate: - Coolant incorrect: - Cooling system component incorrect: - Over Cooling: - Cooling system component incorrect: - Gauge incorrect: - Clutch Operation Faulty: - Clutch slipping: - Clutch not disengaging properly: - Gear Shifting Faulty: - Doesn't go into gear; shift pedal doesn't return: - Jumps out of gear: - Overshifts: - Abnormal Engine Noise: - Knocking: - Piston slap: - Valve noise: - Other noise: - Abnormal Drive Train Noise: - Clutch noise: - Transmission noise: - Drive line noise: - Abnormal Frame Noise: - Front fork noise: - Rear shock absorber noise: - Disc brake noise: - Other noise: - Oil Pressure Warning Light Goes On: - Exhaust Smokes Excessively: - White smoke: - Black smoke: - Brown smoke: - Handling and/or Stability Unsatisfactory: - Handlebar hard to turn: - Handlebar shakes or excessively vibrates: - Handlebar pulls to one side: - Shock absorption unsatisfactory: - Brake Doesn't Hold: - Battery Trouble: - Battery discharged: - Battery overcharged:
Kawasaki ZZR250 - Workshop Manual / Repair Manual - Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
e-mail