Kawasaki KX250F 2013–2014 Service Manual (P/N 99924-1459-02)

Kawasaki’s factory KX250F Motorcycle Service Manual (P/N 99924-1459-02), 2nd Edition (0), dated March 15, 2013, covers the 2013 KX250ZD and 2014 KX250ZE.

Search, Bookmarks, and Wiring Diagrams

Finding procedures and reading diagrams: Search the manual text or use the PDF bookmarks to jump to chapters and individual procedures. Small wire-color codes and connector labels are readable when zoomed in. Those labels are part of the diagram images and are outside the text search.

The download is one printable English PDF with 479 pages, including the front and back covers, the quick-reference and introductory pages, the 18-page appendix, and 12 blank or intentionally blank pages.

Race Maintenance, DFI Diagnosis, and Overhaul

The selected procedures below show the scope of the manual. It also covers spoke tension and rim runout checks.

• Race maintenance: The factory chart schedules inspections and replacement work by race count and operating hours. It covers the engine, clutch, cooling system, drive chain, brakes, and chassis.
• DFI troubleshooting: Follow ECU self-diagnosis and service codes through sensor circuit tests, upstream and downstream injector checks, fuel-pressure and flow tests, fuel-pump checks, and throttle-body service.
• Engine and transmission: Covers engine removal, cylinder-head and timing-chain work, valve-guide and valve-seat service, piston and cylinder inspection, clutch service, crankcase separation, crankshaft and connecting-rod checks, and transmission overhaul.
• Cooling and lubrication: Includes cooling-system pressure testing and bleeding, water-pump service, radiator removal and inspection, oil-pump inspection, and engine oil-pressure testing.
• Brakes: Covers hydraulic bleeding, pad and disc inspection, and front and rear caliper and master-cylinder overhaul.
• Suspension and steering: Covers left-fork compression and rebound damping, right-fork spring preload, rear-shock oil service, Uni-Trak linkage service, and steering-stem bearing work.
• Ignition and charging: Includes flywheel magneto, regulator/rectifier, and ignition tests, plus a launch-control button continuity check for the KX250ZE.

Kawasaki wrote the manual primarily for trained mechanics in a properly equipped shop. Owners with mechanical experience and the specified tools can use it for basic maintenance and selected repairs. Internal engine, DFI, and pressurized suspension work calls for workshop experience and the specified test equipment.

Model-Specific Wiring and Final Drive

The KX250ZE has a launch-control button and a combined launch-control and FI warning indicator. The KX250ZD uses a different FI indicator arrangement. Separate wiring diagrams, ECU identification tables, routing drawings, and suspension specifications help you select the references for your model. The final-drive chapter distinguishes the KX250ZD’s circlip-retained engine sprocket from the KX250ZE’s nut-and-washer arrangement. Country and area codes identify where regional specifications apply.

Diagnostic References, Tools, and Repair Cautions

The DFI wiring diagram, self-diagnosis flow chart, and Kawasaki Diagnostic System connector information help you trace a service code to the correct circuit. The fuel-system chapter explains that the pressure regulator is built into the fuel pump and is serviced with the pump assembly. The appendix provides cable, wire, and hose routing drawings and a symptom-based troubleshooting guide.

Exploded views and chapter tables identify fasteners, replacement items, lubrication and locking-agent points, tightening sequences, fluid capacities, wear limits, and electrical test values. Factory tool references include the crankcase splitting tool assembly (57001-1362), valve spring compressor assembly (57001-241), fork spring compressor (57001-1771), and top plug wrench (57001-1645). DFI and ignition tests reference the measuring adapter (57001-1700), needle adapter set (57001-1457), and peak voltage adapter (57001-1415).

An oil-filter grommet installed inside out can block oil flow and seize the engine. Incorrect camshaft-chain timing can damage the valves. The fork and nitrogen-charged shock procedures include precautions for spring force and stored pressure. Use Kawasaki’s separate Parts Catalog to identify and order replacement parts.

Valve Clearance and Fuel Pressure Examples

For both models, standard valve clearance with the engine cold at room temperature is 0.10–0.15 mm on the intake side and 0.17–0.22 mm on the exhaust side. The DFI fuel-pressure inspection specifies 294 kPa (43 psi) with the engine idling.