Kawasaki KSF250 Mojave ATV 1987–2004 Service Manual (P/N 99924-1067-14)

This Kawasaki KSF250 Mojave All Terrain Vehicle Service Manual is the Fourteenth Edition, dated April 10, 2003, P/N 99924-1067-14. It combines the factory base manual with four integrated supplement chapters for model-specific service information.

PDF Bookmarks and Wiring Detail

Section access and diagram labels: Embedded PDF bookmarks open the main chapters and all four supplements. PDF text search is not available. Small wiring-diagram labels require zooming to read comfortably.

One printable PDF contains 243 pages, including six front-matter pages, 198 pages of base-manual chapters and appendix, 38 supplement pages, and one rear model-application page.

Engine Overhaul, Chassis Service and Electrical Testing

The following selected service topics outline the repair coverage. Other included subjects include air-cleaner servicing and spark-arrester cleaning.

• Engine top end: Step-by-step cylinder-head and piston removal and installation, valve-guide and valve-seat repair, camshaft timing, KACR inspection, and compression testing.

• Crankshaft and transmission: Crankcase splitting and assembly, crankshaft and connecting-rod inspection, balancer service, clutch disassembly, and transmission gear and shift-fork checks.

• Fuel system: Carburetor disassembly and inspection, pilot-screw adjustment, fuel-level and float-height checks, and throttle and choke cable service.

• Cooling system: Pressure testing, flushing, thermostat and radiator-cap inspection, water-pump impeller service, and mechanical-seal replacement.

• Brakes: Caliper and master-cylinder repair, brake-fluid replacement and bleeding, parking-brake adjustment, and brake-pad and disc inspection.

• Chassis and final drive: Chain and sprocket service, rear-axle and hub-bearing work, suspension-arm and swingarm bearings, steering-stem and knuckle service, and wheel alignment.

• Electrical diagnosis: Magneto and flywheel service, ignition-coil, exciter-coil, pickup-coil and CDI tests, lighting-output checks, cooling-fan diagnosis, and model-specific wiring diagrams.

Written primarily for trained mechanics in a properly equipped shop, the manual also supports owners doing basic maintenance and repair who understand tools and workshop procedures.

Model Application and Supplement Use

The model-application table lists 1987 KSF250-A1 through 1997 KSF250-A11, then 2000 KSF250-A14 through 2004 KSF250-A18, with corresponding frame-number entries. 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 earlier sections for procedures and specifications that did not change. That distinction matters when checking a repair value against a specific year.

Cylinder-Head and Bottom-End Repair

Valve work extends to guide replacement and reaming, valve-to-guide clearance checks using the wobble method, and seat cutting supported by a repair flowchart. Cylinder and piston inspection includes bore measurements, oversize boring and honing, ring-groove inspection, and ring end-gap checks.

Cylinder-head bolt tightening sequences and component-specific torque tables accompany the procedures. Tool callouts include Compression Gauge 57001-221 with adapter 57001-1018 or 1183, and Valve Guide Reamer 57001-1079.

Bottom-end coverage includes crankshaft runout and connecting-rod clearance checks, transmission assembly details, reverse-shift mechanism service, and kickstarter assembly. Kawasaki recommends replacing the crankshaft assembly rather than attempting component replacement; crankshaft disassembly and reassembly require a shop with the necessary tools and equipment. Bearing Driver Set 57001-1129 and Crankshaft Installing Jig 57001-1174 are identified.

Carburetor, Cooling and Lubrication Details

California carburetor specifications are distinguished in the later supplements, including different main-jet entries. Fuel-level inspection identifies Fuel Level Gauge 57001-1017.

Overtightening the pilot screw can damage the carburetor body, while incorrect impeller handling can damage the water-pump O-ring on the shaft threads.

The lubrication chapter covers oil-flow inspection, oil-screen cleaning, and oil-pump removal, disassembly and inspection. Coolant capacities, thermostat opening temperatures, and radiator-cap test specifications are also tabulated.

Suspension, Steering and Final-Drive Limits

Suspension inspection distinguishes bearing, sleeve and seal wear from shock-absorber faults. The front shocks are sealed units with external inspection procedures; the A2/A3 supplement also specifies that the rear shock spring cannot be removed.

The rear-sprocket warning links incorrect installation with uneven flange seating, excessive runout and chain loss that can lead to rear-wheel lockup.

Electrical Tests and Diagnostic References

Ignition diagnosis includes both arcing-distance and resistance tests. The manual explains that resistance testing cannot detect every insulation fault, giving the mechanic a reason to compare test results rather than treating a normal resistance reading as conclusive.

Magneto work identifies Rotor Holder 57001-1184 and Rotor Puller 57001-1216. Later supplements add voltage-regulator, reverse/neutral-switch, and brake-light-switch information.

Named references include the Engine Oil Flow Chart, Camshaft Chain Timing view, Valve Seat Repair flowchart, Ignition System Circuit, Cooling Fan Circuit, and model-specific KSF250 wiring diagrams. The appendix adds a symptom-based Troubleshooting Guide for starting difficulties, overheating, shifting faults, handling problems and poor braking.

Selected Valve, Cooling and Supplement Specifications

Cold intake and exhaust valve clearance is 0.20–0.24 mm. The radiator-cap inspection specifies a relief-pressure range of 73.5–103 kPa.

For KSF250-A17/A18, the carburetor table specifies a float height of 17 ± 1 mm. The same supplement distinguishes engine-oil fills of 1.8 L without filter removal, 1.9 L with the filter removed, and 2.0 L when the engine is completely dry.

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.