2006–2008 Kawasaki KX250F Service Manual (P/N 99924-1459-02)

This 479-page PDF contains Kawasaki's factory KX250F Motorcycle Service Manual, Part No. 99924-1459-02, 2nd Edition (0), dated March 15, 2013, for the liquid-cooled, DOHC four-stroke single-cylinder competition motorcycle. The model-application page identifies the 2013 KX250ZD and 2014 KX250ZE; it does not cover 2006-2008 KX250F models. Kawasaki states that the manual is primarily for trained mechanics in a properly equipped shop. Owners with basic mechanical knowledge, the correct tools, and workshop experience can use it for basic maintenance and selected repair work, while internal engine, DFI, and pressurized-suspension service is better suited to qualified mechanics.

• Exact model application: Coverage begins with frame numbers JKAKXMZC□DA000001 and JKAKX250ZZA000001 for the 2013 KX250ZD, and JKAKXMZC□EA013001 and JKAKX250ZZA013001 for the 2014 KX250ZE. The □ position is a variable digit.
• Race-based maintenance: The factory chart organizes service by races and operating hours rather than street mileage, with procedures for the fuel system, valve train, piston and cylinder, clutch, lubrication, cooling, chain, brakes, wheels, steering, and chassis.
• DFI diagnosis and fuel-system repair: Covers ECU self-diagnosis, service-code reading, sensor circuit testing, upstream and downstream injector checks, fuel-pressure and flow testing, fuel-pump and regulator service, throttle-body work, and the Kawasaki Diagnostic System connector.
• Engine and drivetrain repair: Details cylinder-head removal, camshaft and timing-chain work, valve-guide and valve-seat service, piston and cylinder inspection, clutch service, engine removal, crankcase separation, crankshaft and connecting-rod inspection, and transmission disassembly and assembly.
• Cooling, lubrication, and brake service: Includes cooling-system pressure testing and air bleeding, water-pump and radiator repair, the lubrication-system chart, oil-pump inspection and oil-pressure testing, brake-line bleeding, and caliper and master-cylinder overhaul.
• Suspension, steering, and electrical systems: Explains left-fork compression and rebound damping service and right-fork spring-preload work, plus rear-shock oil service, Uni-Trak linkage repair, steering-stem service, flywheel-magneto testing, charging and ignition checks, and KX250ZE launch-control diagnosis.

Model-Specific References and Factory Tooling

The KX250ZE receives dedicated coverage for its launch-control button and combined launch-control/FI warning indicator. The KX250ZD uses a different FI-indicator arrangement, and the manual separates ECU identification, wiring and cable routing, engine-sprocket retention, and suspension specifications where the two builds differ. Country and area codes for AU, BR, CA, EUR, TH, and US are defined where regional settings or specifications apply.

Illustrations include the DFI System Wiring Diagram, Self-Diagnosis Flow Chart, separate KX250ZD and KX250ZE Wiring Diagrams, the Lubrication System Chart, and model-specific Cable, Wire, and Hose Routing drawings. The appendix adds a system-by-system Troubleshooting Guide. Exploded views throughout the chapters identify fasteners, replacement parts, locking-agent points, lubrication points, and tightening sequences.

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 testing also call out the measuring adapter (57001-1700), needle adapter set (57001-1457), and peak voltage adapter (57001-1415).

Specifications, Repair Cautions, and Scope

Chapter-specific tables provide torque and locking-agent data, fluid specifications and capacities, service limits, wear and runout limits, pressure-test data, valve and suspension adjustments, and electrical resistance, voltage, and peak-voltage values.

The repair cautions are specific to this machine. Installing the oil-filter grommet inside out can stop oil flow and seize the engine, while incorrect camshaft-chain timing can damage the valves. Front-fork and rear-shock work also demands the specified tooling and safety procedures: spring force can eject a fork tool, and the nitrogen-charged shock can expel oil and internal parts if pressure is handled incorrectly.

This publication is a service and repair manual, not a parts catalog; Kawasaki directs spare-parts identification to the separate Parts Catalog.