Kawasaki KSF250 Mojave All Terrain Vehicle 1987–2004 OEM Service Manual (P/N 99924-1067-14)

Need exact Kawasaki specs for a Mojave 250 in your bay? This Kawasaki KSF250 Mojave All Terrain Vehicle Service Manual is the Fourteenth Edition dated April 10, 2003, identified on the publication as Part No. 99924-1067-14. The supplied PDF contains 243 pages and is built around Kawasaki's own model-application and supplement structure rather than a generic 250cc ATV reference.

Model Application and Manual Structure

The model-application table lists 1987 KSF250-A1 through 1997 KSF250-A11, then 2000 KSF250-A14 through 2004 KSF250-A18. It also gives year-specific starting frame numbers, beginning with JKASFMA1□HB500001 for the 1987 A1 and extending through JKASFMA1□4B538001 / JKASF250AAB605001 for the 2004 A18. The square symbol is the variable frame-number digit used in Kawasaki's table. No 1998 or 1999 model application is listed.

Later machines are handled through cumulative supplements: 1988–1989 (A2/A3), 1990–1997 (A4–A11), 2000–2002 (A14–A16), and 2003–2004 (A17–A18). Each supplement directs the mechanic back to the earlier base sections for procedures and specifications that did not change. That distinction matters when checking a repair value against a specific year.

Component and System Coverage

Coverage runs from fuel and cooling systems through complete engine, chassis, brake, and electrical repair work. Factory procedures include Keihin CVK34 pilot-screw, fuel-level, and float-height checks; cooling-system pressure testing and flushing; water-pump impeller and mechanical-seal service; camshaft timing, KACR inspection, compression testing, valve clearance, valve-guide and valve-seat work, and piston/cylinder measurement.

Deeper repair sections cover clutch disassembly and inspection, engine removal/installation, crankcase splitting, crankshaft runout and connecting-rod clearance checks, transmission gear and shift-fork inspection, final-drive chain and sprocket service, rear-axle runout, hub bearings, suspension-arm and swingarm bearings, steering-stem and knuckle service, brake-caliper and master-cylinder repair, brake-fluid replacement and bleeding, and tire/wheel alignment work.

Electrical diagnosis goes well beyond a basic wire-color chart. The manual covers magneto/flywheel service, ignition timing, ignition-coil arcing and resistance tests, exciter-coil and pickup-coil checks, CDI-unit resistance testing, lighting output, cooling-fan circuits, switches, and wiring inspection. Named visual references include the Engine Lubrication System flow diagram, Camshaft Chain Timing, the Valve Seat Repair flowchart, Ignition System Circuit, Cooling Fan Circuit, and model-specific KSF250 wiring diagrams in the base manual and supplements.

Technical Specification Highlights

The core engine specification is a 249 mL liquid-cooled DOHC single, with a 74.0 × 58.0 mm bore and stroke, 11.0:1 compression ratio, Keihin CVK34 carburetor, wet multi-disc clutch, and five-speed-plus-reverse constant-mesh return-shift transmission. Cold valve clearance is 0.20–0.24 mm for both intake and exhaust. The 10 mm cylinder-head bolts are specified at 45 N·m (33 ft-lb) and are shown with a tightening sequence.

Cooling data includes a 1.45 L total coolant amount, thermostat opening at 69.5–72.5°C (157–163°F), and a radiator-cap relief range of 73.5–103 kPa (10.7–15 psi). The supplements also preserve year-specific changes instead of forcing one value across the whole run. For example, the 2003–2004 A17/A18 section specifies engine-oil fills of 1.8 L without filter removal, 1.9 L with the filter removed, and 2.0 L when completely dry; its carburetor table specifies a 17 ± 1 mm float height.

Shop-level tool callouts include Fuel Level Gauge 57001-1017, Compression Gauge 57001-221 with adapter 57001-1018 or 1183, Valve Guide Reamer 57001-1079, Bearing Driver Set 57001-1129, Crankshaft Installing Jig 57001-1174, plus Rotor Holder 57001-1184 and Rotor Puller 57001-1216 for magneto work.

The manual also flags several repair traps that matter in real shop work. The water-pump section warns that turning the impeller the wrong way during installation can damage its O-ring on the shaft threads. The carburetor section cautions that overtightening the pilot screw can damage the carburetor body and require replacement. At the final drive, installing the rear sprocket backward can misalign the chain, create excessive runout and wear, and in the worst case contribute to rear-wheel lockup.

Safety Notice: The technical data and specifications contained in this document are provided for reference and component identification purposes. Always consult a certified technician before performing complex mechanical service or diagnostic work on this equipment.