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Crossfire xz250r V4, Owner'S Manual

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Crossfire xz250r V4 Owner'S Manual Download Page 64

 

64 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 

 

 

 

 

 

 

 
Odometer or Hour Reading 

         00,000                      km 
                                            hr. 
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                           km 
                                            hr. 
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                           km 
                                            hr. 
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                            km 
                                             hr. 
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                           km 
                                            hr. 
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                           km 
                                            hr. 
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                           km 
                                            hr. 
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                           km 
                                            hr.  
 

Dealer Stamp 

 

Date 

Signature 

 
Odometer or Hour Reading 

                                           km 
                                            hr. 
 

Dealer Stamp 

 

Date 

Signature 

MAINTENANCE SCHEDULE RECORD 

 

 

 

 

 

THE FIRST OIL CHANGE MUST BE DONE BEFORE THE FIRST INITIAL RIDE. 

         

 

    

 

  

NOTICE

 

Summary of Contents for xz250r V4

Page 1: ...1...

Page 2: ...if it is resold This manual contains the latest product information available before printing Crossfire Motorcycle Pty Ltd reserves the right to make changes at any time without notice and without inc...

Page 3: ...al Crossfire dealer for information IMPORTANT PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU US...

Page 4: ...thout limiting the above this warranty is Voided with respect to any product that has been used for rental or commercial purposes or that sustained the following damage Bent or broken frame or swing a...

Page 5: ...ING AIR FILTER THROTTLE SYSTEM ENGINE IDLE SPEED CLUTCH SYSTEM SPARK PLUG BRAKING SYSTEM BRAKE ADJUSTMENT BRAKE FLUID CHECK ADDING BRAKE FLUID BRAKE PADS BRAKE SYSTEM BLEEDING SUSPENSION SYSTEM FRONT...

Page 6: ...eded by a symbol This information is intended to help you avoid damage to your motorcycle and or property around you This manual covers basic maintenance procedures A detailed parts diagram manual is...

Page 7: ...must use your own good judgment Safety information will come in a variety of different forms including Safety Labels on the Motorcycle Safety Messages preceded by a safety symbol and one of these sign...

Page 8: ...result in serious injury or death Ride Off Road Only This motorcycle has been designed and manufactured for off road use only The motorcycle is not equipped with lights turn signals horn and other fe...

Page 9: ...your child think through problems and come to logical conclusions Does your child obey your rules when they ride their bicycle If your child makes bad judgments takes un warranted risks and or does no...

Page 10: ...els warn you of potential hazards Others will provide important safety and maintenance information Please read them carefully and do not remove them If your label wears off from riding or becomes hard...

Page 11: ...at them Please read this section carefully before you ride your motorcycle This section of the manual will describe the function location and operation of all the basic controls of your motorcycle COM...

Page 12: ...12 COMPONENT LOCATIONS Rear Brake Pedal Spark Plug Oil Filter Kick Starter Battery Drive Chain Fuel Valve Air Filter Shift Lever Engine Number Chassis Number Side Stand CDI Box...

Page 13: ...mber is stamped On the left side of the engine under the countershaft Sprocket Write this number is the Engine Number box on page 3 Clutch Lever The clutch lever is located on the left side of the han...

Page 14: ...nition key is used to supply power from the battery to the electrical components of the motorcycle Turn the switch to the OFF position when you are finished riding or if you wish to stop the engine Fu...

Page 15: ...ing the choke lever the cylinder is closed again Choke Lever XZ250R LC ZS When pulling the choke lever fully toward the top a cylinder Shift Lever The shift lever is on the left side of the engine The...

Page 16: ...ide Stand Push the side stand to the ground and tilt the motorcycle to the left Make sure the bike is on solid ground and the position is secure You can use the band to secure the stand when riding of...

Page 17: ...protection is not possible wearing the proper gear can reduce the chance of and severity of injuries when you ride Helmets Eye Protection Your helmet is your most important piece of riding gear becaus...

Page 18: ...is manual Brake Hoses Inspect the brake hoses for leaks and replace if needed Nuts Bolts Inspect all accessible nuts and bolts Tighten then if it is needed Spark Plug Cap Check the spark plug for loos...

Page 19: ...rn the key switch to the ON position Pg 12 2 Make sure the transmission is in the neutral position 3 Turn the fuel tap to the ON position Pg 12 4 Pull and hold the choke lever Pg 13 XZ250R V4 5 Lift t...

Page 20: ...s to start after repeated attempts it may be flooded with excess fuel Follow the steps below to clear a flooded engine 1 Press the engine stop switch and hold it 2 Open the throttle completely 3 Press...

Page 21: ...n to shift gears will come with riding experience Up shift into a higher gear when you hear the engine speed rpm get too high When the engine rpm gets too high in a gear you will feel the motorcycle s...

Page 22: ...e brake controls and steer straight ahead until you regain control of the motorcycle Once you have control reapply the brakes with less force Generally reduce your speed and complete your braking befo...

Page 23: ...u operate the engine 2 Burns From Hot Motorcycle Parts Let the engine and exhaust system cool off before you touch them 3 Injury From Moving Parts Do not run the engine unless instructed to do so Read...

Page 24: ...st Crossfire dealer If you decide to do your own maintenance use only replacement parts that you have purchased from an Crossfire dealer or parts purchased directly from Crossfire This will ensure the...

Page 25: ...nleaded fuel is recommended because it produces fewer engine deposits and extends the life of the engine and exhaust components Never use stale or contaminated gasoline Never use gasoline that has bee...

Page 26: ...ce the level is low Inspect the coolant level before each ride Coolant loss through the overflow tube is normal But if loss is more than normal inspect the cooling system Cooling System Inspection 1 C...

Page 27: ...r the right or left 4 Remove the oil filler cap wipe it clean and insert it back in to its place but DO NOT screw it back in 5 Check that the oil level is within the 1 2 hash marks on the dip stick as...

Page 28: ...you do not need to add oil 7 If the oil level is at or near the lower mark 2 you need to add oil 8 Add the recommended oil until the upper mark 1 is reached DO NOT OVERFILL 9 You can also check the o...

Page 29: ...11 Remove the filter from the filter cover 12 Remove the spring in the filter 13 Check and see if the cover O ring is in good condition 14 After the oil is drained out of the filter chamber install a...

Page 30: ...end 9 Once the filter is removed wash it clean with a non flammable cleaning solvent Then wash in hot soapy water rinse well Then allow the filter to dry well 10 If the filter is damaged replace it wi...

Page 31: ...ction will increase free play 5 Operate the throttle to ensure that it is functioning smoothly and when released it returns completely from fully open to fully closed in all steering positions 6 Inspe...

Page 32: ...ff 2 Connect a tachometer to the engine 3 Make sure the transmission is in neutral gear 4 Keep the motorcycle in an upright position 5 Adjust the idle speed with the stop screw 6 To increase the idle...

Page 33: ...the lock nut and turn the internal cable adjuster to adjust free play 4 Once you are satisfied with the adjustment tighten the lock nut 5 If the adjuster is threaded out near its limit or the correct...

Page 34: ...in and shift into gear Make sure the engine does not stall and the motorcycle does not creep forward 5 Gradually release the clutch lever and open the throttle The motorcycle should move smoothly and...

Page 35: ...ts store The spark plug gap should be 02 03 in 0 6 0 7mm Always check the gap of a new spark plug before you install it 8 Be sure all dirt has been cleaned from the threads Install the spark plug by h...

Page 36: ...tion is reached 1 Loosen the nut and turn the adjuster to either direction for the desired height 2 The height of the lever should approximately be level with the height of the foot rest 1 Check the l...

Page 37: ...master cylinder cap 2 Remove the cap screws with a Phillips head screwdriver 3 Remove the cap Be careful not to damage the diaphragm gasket that is seated under the cap 4 Add the required amount in t...

Page 38: ...ycle for servicing Because the brake system utilizes fluid any air bubbles inside the brake system will cause you to lose braking efficiency Air generally enters the brake system when the motorcycle s...

Page 39: ...ll have the writing S H meaning Soft Hard or the marks or This is the Compression Adjuster 3 If you turn the screw toward the H the downward action of the fork will harden Alternatively if you turn th...

Page 40: ...er or not replacement parts or service is required Your motorcycle is new Break it in for about 2 hours with the original settings before attempting adjustments 1 Move the motorcycle by bouncing it up...

Page 41: ...e or counter clockwise to make changes This affects how quickly or how slowly the shock works during compression over small rough bumpy terrain 4 Softening the nut can help make the bike ride more smo...

Page 42: ...ntil it will no longer turn DO NOT FORCE This is the full hard setting 4 Turn the adjuster counter clockwise 6 to 9 clicks Slow setting 1 The rebound damping adjuster is located at the lower end of th...

Page 43: ...combination of handling tread life and riding comfort Generally speaking underinflated tires will wear unevenly and adversely affect handling Underinflated tires are also more likely to fail from bei...

Page 44: ...not have the same reliability as a new one and could fail while riding For more information on a temporary repair see the section titled Resolving the Unexpected Always use replacement tubes that are...

Page 45: ...he slack should remain constant through out If it is not some links may be kinked and binding Lubricating the chain will often stop this 3 Inspect the drive chain for the following damaged rollers loo...

Page 46: ...been worn down beyond the two points marked in Fig 1 then the roller s must be replaced 4 If you cannot or do not know how take the motorcycle to a Crossfire dealer for service Fig 1 THE USE OF A NEW...

Page 47: ...be replaced Fig 1 1 Check the guide slider for wear Fig 2 2 Replace the guide slider if it is worn to the bottom of the wear limit Fig 3 Fig 2 Fig 3 THE SLIDERS MUST BE REPLACED IF WORN DOWN TOO FAR...

Page 48: ...ting plate with the same reference marks on both sides of the swing arm 5 Tighten the axle nut to 85ft lbs 115 Nm 6 Re check chain slack and readjust if necessary Fig 1 Commercially prepared chain lub...

Page 49: ...er link is the most critical element of drive chain security Master links are reusable as long as they are in excellent condition We recommend installing a new master link when you install a new drive...

Page 50: ...tch Loose or corroded wires and or connectors always clean bad electrical connections Yes SEE STEP 4 4 Cylinder Compression Test Perform a simple compression test by kick starting the engine slowly Be...

Page 51: ...e engine speed increase No Clogged air filter Restricted or clogged fuel line and or fuel filter Clogged muffler spark arrester Choke valve is closed Clogged fuel tank breather hose Yes SEE STEP 5 5 S...

Page 52: ...See your local Crossfire dealer or motorcycle repair shop to have the ignition timing and engine lubrication system inspected Only attempt these procedures if you are qualified and have the proper to...

Page 53: ...ignition timing normal Timing is non adjustable No Faulty CDI ignition box Faulty ignition pulse generator Yes See your Crossfire dealer to have your motorcycle serviced 1 Examine the Fuel Line Disco...

Page 54: ...earing play Bent Rim Improperly installed wheel hub Damaged swing arm Bent frame Loose or broken spokes Old tires with dry rot The motorcycle pulls to one side Front and rear wheels out of alignment F...

Page 55: ...le 3 Do not continue riding if you are hurt or if your motorcycle is not in safe riding condition Recommendations for specific problems follow If the engine was not making unusual noises before it qui...

Page 56: ...ightness of critical nuts and bolts such as the handle bars control levers brakes and wheels If there is minor damage or you are not sure about possible damage but decide to ride back to your base rid...

Page 57: ...57 TORQUE SPECIFICATIONS Q G C D F E A H L J K M S U T R V Z Q Y A B N O W X P AD AC AF AE AL AK AJ AH AQ AP AM AN AO AR AS AT AU AV AW AX AB AA G D AY A1...

Page 58: ...s 6 7 5 3 AU Connecting rod rear 60 7 45 2 AV Shock mount lower 48 6 36 2 AW Kick stand bolt 40 5 30 3 AX Connecting rod front 60 7 45 2 AY Linkage connection 64 8 48 2 Name Torque Notes N m ft lbs A...

Page 59: ...A Engine Front 35 26 B Oil Drain Cap 17 5 13 C Engine mount lower 40 5 30 D Sprocket Bolts 16 2 12 E Swing Arm bolt 81 60 F Engine mount upper 54 40 G Engine Top 51 38 H Brake Lever 29 7 22 3 J Kick S...

Page 60: ...5 26 B Oil Drain Bolt 17 5 13 C Engine mount lower 40 5 30 D Sprocket Bolts 16 2 12 E Swing Arm bolt 81 60 F Engine mount upper 54 40 G Engine Top 51 38 H Brake Lever 29 7 22 J Kick Starter bolt 33 7...

Page 61: ...mount upper 40 5 30 3 D Sprocket cover bolts 16 2 12 E Sprocket bolt 48 6 36 2 F Engine mount lower 40 5 30 2 G Oil filter screen 13 5 10 H Oil drain bolt 17 5 13 3 J Swing arm bolt 81 60 2 K Kick st...

Page 62: ...1 10 0 1 11 5 1 Fuel 89 Octane or Higher 89 Octane or Higher 91 Octane or Higher required Oil 15w40 Ignition Timing 11 BTDC 2000 Rpm 15 BTDC 2000 Rpm 8 BTDC 2000 Rpm Ignition Type CDI Spark Plug D8RTC...

Page 63: ...t Brake Disc Brakes with 240mm disc floating dual piston caliper Rear Brake Disc Brakes with 240mm disc floating single piston caliper Front Tire 80 100 21 Air Pressure 20 Psi 138 kPa Rear Tire 110 10...

Page 64: ...aler Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signatu...

Page 65: ...65 NOTES...

Page 66: ...66 NOTES...

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