2009 Kawasaki KX250F Motorcycle Service Manual

Detailed service and repair manual for the 2009 Kawasaki KX250F. Covers engine, chassis, and electrical systems with step-by-step procedures and diagrams. Part number 99960-1064-04.

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Document Details

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Document Number / Seller:
31634 / Mark Harris
File Size:
7.39 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Mar 23, 2025

Models Covered & Key Technical Specifications

Kawasaki KX250F (99960-1064-04) - 2009-2012

Technical diagrams and procedures for motorcycle maintenance and overhaul. | Kawasaki Motorcycle Binder.

  • Reference Data: Engine oil capacity requires 1.0 L (1.1 US qt.) for complete dry fill Specifications.
  • Approved Grade: Castrol POWER1 R4 RACING 5W-40 or API SG, SH, SJ, or SL with JASO MA, MA1, or MA2 is the recommended engine oil Grade.
  • Designated Viscosity: SAE 10W-30, 10W-40, or 10W-50 viscosity is specified for optimal oil performance Requirements.
  • Certified Capacity: The engine requires 0.75 L (0.79 US qt) for oil change when filter is not removed Threshold.
  • Factory Standard: For valve clearance, exhaust measures 0.17-0.22 mm, and inlet is 0.10-0.15 mm Mapping.
  • Fundamental Specifications: Front brake pad lining thickness is a standard 4.0 mm (0.16 in.), with a service limit of 1 mm (0.04 in.) Configuration.

Professional Workshop Service Manual & Technical Specifications

Kawasaki KX250F Motorcycle Service Manual: 2008-2012

Machine-Range: 2009 Kawasaki KX250F // Technical-Benchmarks: Motorcycle / Engine Lubrication System Logic // Machine-Range: Detailed Specifications.

Table of Contents Summary

  • Engine Oil and Oil Filter
  • Clutch
  • Valves
  • Cooling System
  • Cylinder and Piston
  • Carburetor

Systems Covered

This manual provides a detailed overview of the Kawasaki KX250F's various systems. It documents procedures for the engine's top end, including camshafts and cylinders, as well as the lubrication system, clutch, and cooling system. Specific sections detail the fuel system, focusing on the carburetor and air cleaner.

Ignition System and Fuel Delivery

Documentation covers ignition system components and fuel delivery mechanisms. Procedures for throttle grip and cable maintenance, carburetor inspection, and fuel tank servicing are included.

Frame and Suspension

Guidance is provided for inspecting and maintaining the motorcycle's frame and suspension. Specific instructions for steering stem bearing lubrication and front fork oil changes are outlined.

Brake System and Electrical Components

The manual details brake system maintenance, including pad wear inspection and fluid changes. Electrical system checks and spark plug replacement are also documented.

Torque Specifications

This manual documents torque specifications for engine components, such as cylinder head bolts (M10), to ensure proper service interval reliability.

FAQ

Specify the **applicable** lubrication requirements for the engine? keyboard_arrow_down

0.75 L (0.79 US qt) of engine oil is required for an oil change when the filter is not removed, ensuring optimal lubrication for the engine and clutch.

What is the **exact** testing parameters for the valve clearance? keyboard_arrow_down

For valve clearance, the standard exhaust measurement is 0.17-0.22 mm (0.0067-0.0087 in.), while the inlet clearance is 0.10-0.15 mm (0.0039-0.0059 in.).

Calculate the **specific** diagnostic procedures for the clutch plates? keyboard_arrow_down

Friction plate thickness is standard at 2.72-2.88 mm (0.107-0.113 in.), with a service limit of 2.5 mm (0.10 in.). Steel plates are standard at 1.5-1.7 mm (0.059-0.067 in.), with a service limit of 1.4 mm (0.055 in.).

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I found this manual to be very thorough. It covers everything you need to know. Customer support was also fantastic; they responded quickly to my queries!
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This manual is incredibly detailed and easy to follow. The diagrams are a lifesaver! Plus, the download process was seamless and I received my email with the link almost instantly.