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Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 65: ...65 NOTES...
Страница 66: ...66 NOTES...
