Crossfire XZ250R Manual Download PDF
Crossfire XZ250R Manual Download PDF
Crossfire XZ250R Manual Download PDF
XZ250R - LC
XZ250R - ZS
XZ250R V4
Owner’s Manual
This manual should be considered a permanent part of the motorcycle and should
remain 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 incurring any obligation.
No part of this publication may be reproduced without written permission.
© 2010-2011 Crossfire Motorcycle Pty Ltd.
2
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 USE AND HANDLE
YOUR BIKE PROPERLY.
Please write the serial numbers of your motorcycle in the boxes below
Engine Number
Dealer Stamp
Crossfire Motorcycle Pty Ltd. reserves the right to modify any equipment, technical
specifications, colors, materials, services offered and rendered, and the like so as to adapt them to
local conditions without previous announcement and without giving reasons, or to cancel any of
the above items without substituting them with others. It shall be acceptable to stop
manufacturing a certain model without prior notice. In the event of such modifications, please ask
your local Crossfire dealer for information.
3
LIMITED WARRANTY
WHAT IS COVERED: Crossfire Motorcycle Pty Ltd. warrants that this product is free of defects in material and
workmanship for a period of 6 months from the date of purchase, except as limited below. Warranty service and
replacement parts are warranted only for the duration of the warranty on the original product. The warranty
coverage is for the following:
Engine and drive train
Front suspension
Rear suspension
Frame and swing-arm
WHAT IS NOT COVERED: This warranty does not cover any conditions caused by misuse, neglect, negligence,
accident operation in any way contrary to the operating instructions in the owner’s manual, normal wear, alteration,
modification, improper or inadequate maintenance, use of unauthorized replacement parts, or service provided by
anyone other than an authorized Crossfire service center and/or dealer. This warranty does not cover transportation
costs for warranty service. Without 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-arm due to abuse
Bent or broken wheels due to abuse
Bent or broken plastic shrouds due to abuse
Any sign of impact, accident, spin-outs or roll over not caused by the condition for which the warranty
coverage is sought.
TO GET SERVICE: Contact your nearest Crossfire service center and/or dealer. The cost of transportation of the
product to and from the service center and/or dealer must be paid by the owner.
Crossfires obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective
parts and Crossfire does not assume or authorize anyone to assume for them any other obligation. No service center
and/or dealer is authorized to modify this warranty.
All implied warranties are limited in duration to the stated warranty period, and are hereby expressly disclaimed in
their entirety after the expiration of the stated 6 month warranty period.
4
CONTENTS
5
INTRODUCTION
Your Crossfire dirt bike was designed as a recreational motorcycle for off-road use only by a
single rider only. This motorcycle is ideal for riders with basic experience.
Before riding, take plenty of time to get acquainted with your motorcycle and how it works.
To protect your investment, we urge you to keep your motorcycle well maintained. In
addition to regular maintenance, it is just as important to observe and perform all pre-ride
and periodic checks detailed in this manual. We also recommend that you read this manual
before you begin riding. In this manual you will find safety information, facts, instructions,
helpful tips and illustrations. To make it easy to use, the manual contains a table of contents
and an index at the end of the manual.
As you read through this manual, you will find information that is preceded 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 available and it can be purchased separately from Crossfire. The parts
manual will be helpful to those with the mechanical skills and tools required to service their
own motorcycle.
Whenever you ride, tread lightly. By staying on established trails and riding in approved areas,
you will help protect the environment and keep off-road riding areas open for future use.
If you have any questions or you need any special service or repair, remember that your
Crossfire dealer knows your motorcycle best and will be dedicated to your complete satisfaction.
Replacement parts and technical support can be obtained through your Crossfire dealer. Please
be sure to register your motorcycle with Crossfire and report any address changes so that we
may contact you in the future concerning important product information.
6
IMPORTANT SAFETY INFORMATION
Your personal safety, and the safety of those around you, is extremely important. Operating this motorcycle
safely is an important responsibility. Crossfire Motorcycle Pty Ltd. has provided operating procedures and
other information on labels and in this manual to help you make informed decisions about safety. This
information will alert you to potential hazards that could harm you or others.
It is understood that it is not practical or possible to warn you about all possible hazards associated with
operating and maintaining a motorcycle. You must use your own good judgment.
Safety Messages preceded by a safety symbol and one of these signal words:
This entire manual is filled with important safety information - please read it carefully.
7
IMPORTANT SAFETY INFORMATION
A motorcycle can provide many years of service and pleasure, provided you take responsibility for safety,
properly maintain your motorcycle and understand the challenges you may encounter while riding.
This motorcycle has been designed for younger riders. However, not all youngsters meet the physical and
emotional levels that are needed for riding. Before parents allow any children to ride this motorcycle, we
strongly recommend that they read this entire manual so that they are fully informed before deciding if their
children are ready to ride. Listed below are some of the most important safety measures one should take
when riding.
Never Ride Without a Helmet. The following statement is a proven fact: ``Helmets
significantly reduce the number and severity of head injuries.” Never ride your motorcycle without a helmet.
Even a crash at slow speed can result in a fatal head injury if you are not wearing a helmet. Crossfire
recommends wearing helmets that have been certified for safety by helmet testing organizations that are
independent from the helmet manufacturer. We also recommend that you wear eye protection, boots, gloves,
and other protective gear such as off-road riding pants.
Never Carry a Passenger. This motorcycle has been designed for ONE rider only. There are
no passenger pegs, footrests, handles or seat room for a passenger. Riding with a passenger can interfere
with your ability to operate and/or control the motorcycle and may 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 features required to drive a
motorcycle on public roads. The tires are not designed for pavement and will make the motorcycle unstable
if it is ridden on pavement. If you have to cross a paved road, dismount and walk the motorcycle across the
road.
Ride Within Your Limits. Never attempt to ride your motorcycle in a manner that is beyond
your skill level. It takes time to learn off-road riding skills. Learn to ride your motorcycle step by step. Start
by practicing on safe terrain at slow speeds and gradually build your skill level. Instruction from an
experienced rider(s) is highly recommended. Remember that alcohol, drug use, fatigue and ignorance can
reduce your ability to make good decisions and ride safely.
Be Alert for Hazards. The terrain in which you ride can present many hazards. Always “scan”
the terrain ahead of you continually. Watch for un-expected turns, drop-offs, ditches, rocks and other
hazards. Always maintain a speed slow enough to allow you enough time to see and react to hazards.
Do Not Drink and Ride. Even one drink can impair your ability to ride a motorcycle safely.
Each drink afterward will make the impairment worse. Do not drink and ride. Do not let your friend‟s drink
and ride. Remember, in most states throughout the United States, you can be arrested and charged with
Driving Under the Influence (DUI) if you are riding a motorcycle while intoxicated. This applies to off-road
motorcycles as well.
8
IMPORTANT SAFETY INFORMATION FOR PARENTS
As a parent, your child‟s safety is your first priority. Riding an off-road motorcycle is very fun. However,
just like riding a bicycle, bad decisions can result in injury. As a parent, you can greatly prevent
accidents by making informed decisions about if, when and how your child will ride. Always supervise
your child when he/she is riding.
Before you allow your child to ride, you need to decide if he/she is capable of riding. Riding readiness
can vary tremendously from one person to another. Age and size are not being the only factors that help
determine one‟s riding readiness. There are three other factors that you should also consider before
deciding if your child is ready to ride.
First, consider the physical ability of your child. Riders must be able to hold the motorcycle up, get on,
and sit comfortably with both feet on the ground. The rider must also be able to reach all of the controls
on the handlebars and work the brakes and clutch. Second, consider your child‟s athletic ability. Your
child should be good at riding a bicycle before riding a motorcycle. Determine if your child can judge
speeds and distances while riding a bicycle and react with the proper hand and foot actions. Any person
who does not have good coordination, balance, and agility should not ride this motorcycle.
Finally, determine your child‟s level of mental maturity. It is imperative that you are honest with
yourself when you ask yourself the following questions: Does 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 not obey your rules, they should not ride this
motorcycle.
If you have decided that your child is ready to ride, please remember the following points and never let
your child ride without a helmet. It is up to you (parent) to ensure your child‟s safety, even if they learn
to ride from another experienced adult. Never push your child to try things faster than they are willing or
capable. Always supervise your child when they are riding and regularly remind them about safety rules.
As a parent it is your responsibility to be sure that the motorcycle is properly maintained and kept in safe
operating condition.
Modifying this motorcycle or using parts not manufactured by Crossfire can make your motorcycle
unsafe. Before you consider making any modifications or adding an accessory, please read the following
information carefully.
Improper accessories or modifications can cause a crash in which you can be seriously
hurt or killed. Follow all instructions in this owner‟s manual regarding modifications and accessories.
Crossfire Corp. strongly recommends that you do not remove any original equipment or modify your
motorcycle in any way that may alter the design and/or operation. Such a change could drastically
impair the stability, handling, acceleration, and braking capabilities of the motorcycle and cause a crash.
We also strongly suggest that you do not make any modifications to the exhaust system components.
9
SAFETY LABEL INFORMATION
This page will show you where to find the safety labels on your motorcycle. You will find that some
labels 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
to read, contact your Crossfire dealer for a replacement.
2 3
4 6
1 5
2
1
6
5
4
10
COMPONENT LOCATIONS
When you ride a motorcycle off-road, you need to be able to operate the throttle, clutch, brakes, and other
controls without stopping to look 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.
Clutch Lever
Throttle
11
COMPONENT LOCATIONS
Battery
CDI Box
Spark Plug
Kick Starter
Oil Filter
Air Filter
Fuel Valve
Chassis Number
Drive Chain
Shift Lever
Engine Number
Side Stand
12
SERIAL NUMBER LOCATIONS
13
OPERATING CONTROLS
A
Stop Switch
The stop switch A turns off the engine. When this button
is pressed, the ignition circuit is turned off.
Start Switch
The start switch A turns on the engine. When this button
A is pressed, the engine will start. Once started, release the
button.
Key Switch
A
The ignition key A 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.
Fuel Tap
OFF - In this position, the fuel tap is closed. No fuel can
flow to the carburetor.
OFF ON - In this position, the fuel tap in open. This means fuel
can flow to the carburetor. With the lever in this
position, the tank will be emptied.
ON
14
OPERATING CONTROLS
A
Choke Lever (XZ250R – V4)
When pulling the choke lever A toward you, a cylinder in
the carburetor is opened. Through this cylinder, the engine can
take in additional fuel. This results in a rich fuel and air
mixture, which is needed for a cold start.
When releasing the choke lever, the cylinder is closed again.
Shift Lever
A The shift lever A is on the left side of the engine. The gear
positions are shown in the illustration on the left.
15
OPERATING CONTROLS
Side Stand
Push the side stand to the ground A and tilt the
B
motorcycle to the left. Make sure the bike is on solid
ground and the position is secure. You can use the band B
A
to secure the stand when riding off-road.
16
BEFORE RIDING
Before you ride, you must be absolutely sure that you and your motorcycle are ready to ride. To help you
get prepared, this section of the manual will discuss how to evaluate your riding readiness and how to
perform our recommended ore-ride inspection of your motorcycle. If you are a parent, please be sure you
have read the section “Important Safety Information for Parents” on page 8.
For your safety, we strongly recommend that you always wear an approved helmet, eye protection, boots,
gloves, long pants and a long sleeved jersey, shirt or jacket whenever you ride. Although complete
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 because it offers the
best protection against head injuries. A good helmet will be approved by a testing organization
independent of the helmet manufacturer and will have a chin strap that can be tightened securely. Open-
face helmets offer some protection, but a full-face helmet offers the most protection. When purchasing a
helmet, regardless of style, look for DOT (Department of Transportation) sticker (USA only). If the helmet
has been tested by an independent organization such as the Snell Institute, you will usually find their logo
on a tag inside the padding of the helmet.
Additional Riding Gear – In addition to your helmet and eye protection, we also recommend:
1. Sturdy off-road motorcycle boots to help protect your feet, ankles and lower legs.
2. Off-Road motorcycle gloves to protect your hands.
3. Riding pants with knee and hip pads, a riding jersey with elbow pads and a chest/shoulder protector.
WARNING
NOT WEARING A HELMET INCREASES THE CHANCE
OF SERIOUS INJURY OR DEATH IN A CRASH. BE
SURE YOU ALWAYS WEAR YOUR HELMET AND
OTHER PROTECTIVE APPAREL WHEN YOU RIDE.
17
IS THE MOTORCYCLE READY TO RIDE?
Before each and every ride you take, it is extremely important that you inspect the motorcycle and make
sure any problems you find are corrected. A pre-ride inspection is a must because off-road riding can be
very tough on a motorcycle and you do not want to have a breakdown for from help.
PRE-RIDE INSPECTION
18
BASIC OPERATION & RIDING
This section of the manual gives basic information on how to begin riding your motorcycle. In this section
we will cover how to start and stop the engine, how to use the throttle and brakes, how to use the clutch
and shift gears, and things you need to do when you are finished riding.
To protect your new engine and enjoy optimum performance and service life, be sure you break-in your
motorcycle properly. To do this, avoid full throttle starts and rapid acceleration for the first 35 miles
(56 km) of riding. For information about carburetor adjustment(s) for riding in high altitudes, refer to the
servicing section of this manual.
Before riding this motorcycle, be sure you have read this entire manual up to this point including the
section titled “Important Safety Information (Pg. 6, 7 & Pg. 15) & Before Riding”.
Even if you have ridden other motorcycles in the past, take time to get familiar with the way the
motorcycle works and handles. Always practice in a safe are until you have built your skill level to a point at
which it is safe to ride.
CAUTION WARNING
For your safety, avoid starting or operating the Your motorcycle is not equipped with lights.
motorcycle in an enclosed area with poor ventilation, DO NOT ride at night.
such as a garage. The motorcycle’s exhaust gas contains
poisonous carbon monoxide which can collect rapidly in
an enclosed area and result in illness or death.
19
BASIC OPERATION & RIDING
FLOODED ENGINE
If the engine fails 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 the engine start switch and hold it for 5 seconds. (Electric Start)
4. Kick start the engine several time. (Kick Start)
5. If necessary remove the spark plug and let it dry.
6. Once the engine starts, open the throttle ¼ for a few times.
To stop the engine, shift into neutral and push the engine stop switch A on the left side of the handle bar.
A
CAUTION
DO NOT ride your motorcycle with full load and DO NOT
rev up the engine when cold. Since the piston warms up
and expands faster than the water cooled cylinder, this
might cause engine damage. Always let the engine idle
until warm or ride it warm at low RPM speeds.
CAUTION
For your safety, avoid starting or operating the
motorcycle in an enclosed area with poor ventilation,
such as a garage. The motorcycle’s exhaust gas contains
poisonous carbon monoxide which can collect rapidly in
an enclosed area and result in illness or death.
20
SHIFTING GEARS
This motorcycle has five (5) forward gears for the LC & ZS engines and
6 V4 Engine
six (6) forward gears for the V4 engine.
To start riding, after the engine has been warmed up 5 LC / ZS Engine
and the side stand raised:
4
1. Close the throttle and squeeze the clutch lever all the way in.
2. Depress the shift lever form neutral down to first gear. Once 3
the transmission clicks into gear, the shift lever will return back
to the neutral “N” position once you remove your foot. 2
3. Slowly and gradually open the throttle and release the clutch
N
lever in a simultaneous motion. When you feel the clutch begin
to grab and the motorcycle starts to ease forward, you have 1
reached the “friction zone” of the clutch. Gradually open the
throttle more and release the clutch lever completely as the
motorcycle moves forward.
4. When you attain moderate speed, close the throttle and squeeze the clutch lever at the same time.
Raise the shift lever until it clicks into second gear. After shifting, re-open the throttle and release the
clutch lever.
5. To continue shifting up to each higher gear, repeat step 4.
6. To shift down to a lower gear, close the throttle and pull the clutch. Depress the shift lever until you
feel it click into gear. After shifting, re-apply the throttle and release the clutch lever smoothly.
NOTICE
Remember to close the throttle before shifting
gears. Improper shifting may damage the engine,
transmission, and drive train.
Learning when 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 stop accelerating. This is another way to know when to up-shift.
Downshift to a lower gear when you feel the engine lugging at a low rpm. Downshifting is usually done
when you slow down for a turn or when you stop the motorcycle. Downshifting into a lower gear can help
slow down your motorcycle, especially when going down-hill. However, down shifting when the engine
rpm is too high can cause engine damage.
The neutral position of the transmission is located between the first and second gear positions. To shift
into neutral, pull the clutch lever in and depress the shift lever as many times as needed to get into first
gear. Once you are in first gear, pull up on the shift lever ½ the distance required to up-shift into second
gear. You can also shift into neutral from second gear by depressing the shift lever ½ the distance required
to downshift into first gear.
To prevent transmission damage, do not coast or tow the motorcycle for long distances with engine off.
WARNING
Never attempt to start the engine in gear. Doing
so may cause a crash that could result in serious
injury or death.
21
BRAKING TECHNIQUE
This section will cover basic braking technique for your motorcycle. To slow or stop the motorcycle,
squeeze and hold the clutch lever and apply the front brake lever and rear brake pedal firmly and smoothly.
If your speed is reduced a significant amount, you may need to downshift to a lower gear. Gradually
increase your braking pressure as you feel it is needed. When you come to a stop, put your left foot down
first, then the right foot. Do this so that your brake pedal foot remains on the brake pedal until you come to a
complete stop. To prevent the engine from stalling, always pull and hold the clutch lever when slowing to a
complete stop unless you are in neutral.
For maximum braking, close the throttle and firmly apply both the front and rear brake. On a motorcycle,
the front brake accounts for 70% of the total stopping power of the motorcycle. The rear brake only
accounts for 30%. This is because of the weight transfer that occurs when you apply the brakes. When you
must stop quickly, you must use the front brake together with the rear brake.
Remember that you can apply more brake to the front wheel than you can to the rear wheel before it will
lock up and cause a skid. Finding the proper balance between the amount of front and rear brake pressure
you use will come with experience. Attempting an abrupt stop with only the rear brake will likely cause a
skid.
Applying the brakes too hard or too fast can cause the wheels to lock and cause a skid, reducing your control
of the motorcycle. If this happens, release the 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 before you begin a turn. Avoid braking or closing
the throttle quickly while turning. Either of these actions may cause one or both of the wheels to slip. Any
wheel slip will reduce your control over the motorcycle and could cause a crash.
When riding in wet or rainy conditions, or on loose surfaces such as mud or sand, your ability to maneuver
and stop the motorcycle will be reduced. All of your actions should be done in a smooth and steady manner
under these conditions. Rapid acceleration, braking, or turning can cause you to lose control of the
motorcycle. For your safety, exercise extreme caution when riding under wet, rainy, and/or muddy
conditions.
When descending a long, steep grade, use engine compression braking by downshifting with intermittent use
of both brakes.
Lower the side stand, to support your motorcycle. Press and hold the red stop switch on the left side of the
handle bar until your engine stops. If you are through riding for the day, turn the fuel valve to the “OFF”
position. Always park the motorcycle on a flat level surface. If you will be storing the motorcycle for a long
period of time, turn the fuel valve to the “OFF” position while the engine is still running. Open and close the
throttle repeatedly until the engine stops running on its own. Do this to use up any fuel that still remains in
the carburetor. This will help you avoid carburetor problems that can occur when your motorcycle is stored
for long periods of time with gasoline left in the carburetor.
22
MAINTAINING YOUR CROSSFIRE DIRTBIKE
Keeping your motorcycle in perfect operating condition is absolutely essential to your safety. It is also the
best way to protect your investment, get maximum performance, avoid breakdowns, and have more fun. To
help keep your motorcycle well maintained, this section includes a maintenance schedule for required
servicing and step-by-step instructions on how to perform specific maintenance tasks. In this section you
will also find important safety precautions, information on oils, and tips for keeping your Crossfire looking
good.
Careful pre-ride inspections and good maintenance are invaluable because your motorcycle is designed to be
ridden over rough, off-road terrain. To help you properly care for your motorcycle, this section provides you
with a maintenance schedule. The service intervals in this section are based on average riding conditions.
More frequent service is needed if you subject your motorcycle to severe use, such as competition, or ride in
unusually wet and dusty areas. Frequent checks of the air cleaner are very important to help you avoid
engine damage.
Remember, proper maintenance is the responsibility of the owner. Be sure to inspect your motorcycle before
each ride and follow the maintenance schedule in this section.
WARNING
Improperly maintaining this motorcycle or failing to correct a problem before you ride can cause a crash in which you can be
seriously injured or killed. Always follow the inspection and maintenance recommendations and schedules in this manual.
NOTICE TO PARENTS
As a parent, it is up to you to make sure the motorcycle is properly maintained and kept in safe operating condition. For
youngsters, learning how to take care of a motorcycle and perform basic maintenance can be an important part of their
riding experience. However, if you allow a youngster to perform or assist in any maintenance task(s), such as filling the fuel
tank with gasoline, you need to provide close supervision and make sure the task is performed safely.
WARNING
Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Always
follow the procedures and precautions in this manual.
Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate the
following hazards:
1. Carbon Monoxide Poisoning From Engine Exhaust – Be sure you have adequate ventilation whenever
you 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 all instructions before you begin a procedure. Make sure you have all of the tools and skills required.
To help prevent the motorcycle from falling over, park it on a firm, level surface, using the side stand or a
maintenance stand to provide support. To reduce the chance of a fire or explosion, be careful when working
around gasoline. Use only a non-flammable (high flash point) solvent such as kerosene to clean parts. Keep
cigarettes, sparks, and flames away from all fuel related parts.
23
MAINTENANCE SCHEDULE
To keep your motorcycle safe and reliable when you ride, regular inspections and service is required.
Below you will find a maintenance schedule that describes when components need to be inspected or
serviced. The maintenance schedule lists item that can be performed with basic mechanical skills and hand
tools. In addition, the maintenance schedule will list items that involve more extensive procedures and could
require special training, tools and/or equipment.
Because this motorcycle does not have an odometer, service intervals in the maintenance schedule are
expressed in terms of riding days. To avoid missing required maintenance, we suggest that you develop a
good way to record the amount of time you spend riding your monocycle. If you do not feel capable of
performing any of the procedures described in this manual or if you need assistance, please contact your
nearest 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 best
quality and reliability for your motorcycle.
Always perform the pre-ride inspection described on page 16 at each scheduled maintenance interval.
Each item on the maintenance schedule requires some mechanical knowledge. You will find that some items
in the table (marked * and **) may require a higher level of mechanical skill and special tools. If you do not
feel capable of performing any procedure, please consult your nearest Crossfire dealer.
* Indicates items that require a moderate to high level of mechanical skill. We recommend service by an
Crossfire dealer if the owner is not mechanically qualified.
** Indicates items and procedures that require special tools.
Note: Service your motorcycle more frequently when you ride in wet or dusty conditions.
24
BASIC MAINTENANCE PROCEDURES
FUEL (GASOLINE)
Fuel Recommendation – Any unleaded gasoline with an octane rating of 90 or higher.
The engine in your motorcycle has been designed to run on any gasoline with a pump octane rating of 86 or
higher. Most service stations will display the octane rating above each pump. Although it is not required,
Crossfire recommends use of gasoline with a 90 octane rating or higher to ensure maximum performance
and reliability.
Use of a lower octane gasoline can cause pre-detonation in the engine. When this occurs, you will hear a
persistent “pinging” or “spark knock” which, if severe, can cause engine damage. It is however no cause for
concern if you hear light pinging while the engine is under hard acceleration, such as climbing up a hill. If
pinging occurs under normal load and a steady engine speed, switch brands of gasoline and be sure you are
using the proper octane rating. Use of unleaded 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 been mixed with oil. Avoid
getting dust, dirt and water into the fuel tank.
1. Before refueling your motorcycle, check the fuel hoses A for leaks, damage, cracks, or deterioration.
2. Replace the fuel hose if you feel it is necessary.
3. Inspect the fuel filter B , replace if necessary.
4. Twist the fuel tank cap B counter-clockwise C and remove the cap from the tank.
5. Using a funnel, add fuel to the tank until the level reaches about 2 inches from the top of the tank.
6. Twist the fuel cap clockwise D until it is securely tight.
7. Be sure that you have the breather tube connected to the gas tank cap.
B
2
1 A
C
WARNING
Gasoline is highly flammable and explosive. You
can be burned or seriously injured when handling
gasoline. Always stop the engine. Only handle
gasoline outdoors. Clean all spills immediately.
25
BASIC MAINTENANCE PROCEDURES
COOLING SYSTEM
A
26
BASIC MAINTENANCE PROCEDURES
ENGINE OIL
Using proper oil, and regularly checking, adding and changing oil will help extend the service life of your
engine. Even the best oil wears out and becomes thinner. Changing oil helps get rid of dirt and deposits in
the engine. Operating the engine with old or dirty oil may and may damage your engine. Running the
engine with not enough oil can cause serious damage to your engine.
Engine Oil Recommended – SAE 10w40 Motor Oil. *
Indicates oil for regular air temperatures. Please see the oil/air temperature chart to help you choose the
best oil for your climate.
CAUTION
Your motorcycle does not need oil additives. ONLY use the recommended oil. DO NOT use oil with graphite or
molybdenum additives, they may adversely affect the clutch operation. DO NOT use motor oils that display the API
circular logo that is labeled “energy conserving”, they may affect the lubrication and clutch performance.
1. Start and run the engine at idle for 3-5 minutes, then
A
stop it.
2. Wait about 2-3 minutes to allow the oil to properly
distribute itself in the engine.
3. Stand the motorcycle on a support stand so that it is not
leaning to either the right or left.
4. Remove the oil filler cap A , 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 in Fig. 1
XZ250R - LC 6. If the oil level is at or near the upper mark (1), you do
B 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 oil level through the sight glass B
10. Repeat steps 1 through 5.
11. Reinstall the dipstick and check for any leaks.
Fig. 1
27
BASIC MAINTENANCE PROCEDURES
XZ250R - ZS
B Fig. 1
NOTICE
If the oil filter and cap are not installed correctly,
it will cause serious engine damage.
NOTICE
Improper disposal of drained fluids is harmful to
the environment.
NOTICE
Dispose of drained oil in an appropriate manner.
Most parts stores or auto shops do take used oil.
28
BASIC MAINTENANCE PROCEDURES
1. Start and run the engine at idle for 3-5 minutes, then stop
A
it.
2. Stand the motorcycle on a straight level surface so that it
is not leaning to either the right or left & support it.
3. Remove the oil filler cap. (Pg. 27) A
4. Place the oil drain pan under the engine on the left side.
5. Remove the oil drain bolt A and sealing washer B .
B 6. As the oil in draining out, press and hold the engine stop
button and the starter button. The engine will turn but
C will not start. This will allow all the oil to be drained from
XZ250R - LC E the engine. (ONLY FOR 5 SECONDS)
7. After the oil has drained, apply fresh engine oil to the
drain bolt threads.
8. Install and tighten the drain bolt with a new sealing
B washer to 11ft lbs. (15Nm)
A 9. It is recommended to replace the oil and filter after every
15 hours of riding.
10. Remove the oil filter cover bolts C and the oil filter E
cover.
11. Remove the filter from the filter cover.
12. Remove the spring in the filter.
C
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
XZ250R - ZS
new filter back in to the filter chamber.
15. Make sure the rubber seal is facing out toward the filter
cover. You will see the “OUT-SIDE” words on the filter
body, near the rubber seal.
16. Install the spring in to the new oil filter.
B 17. Apply clean engine oil to the O-ring and install it to the oil
A
filter cover.
18. Install the filter cover, be careful not to damage the O-
ring, tighten the filter cover bolts to 9ft lbs. (12 Nm).
19. For the XZ250R V4 engine series, there are 2 screen filters
that also need to be replaced when doing an oil change.
C Fig. 1 C & Fig. 2 D
20. Fill the crankcase with the recommended oil only.
XZ250R V4 21. Install the oil filler cap.
22. Check the oil level by following the steps in “Checking &
Adding Oil”.
C D
Fig. 1 Fig. 2
29
BASIC MAINTENANCE PROCEDURES
AIR FILTER
Proper air filter maintenance is extremely important for off-road vehicles. A dirty, water-soaked, worn-out
air filter will allow dirt, dust, mud or other impurities to pass into the engine. If you are riding in wet and/or
muddy areas, you should service the air filter more often. Always replace the air filter with a genuine
Crossfire filter specifically designed for your model or a filter of equal quality.
Failure to maintain the filter can/may cause engine wear or damage, expensive repairs, low engine power,
low fuel mileage, carbon build up on valves and foul the spark plug.
2 3 NOTICE
Improper or lack of proper air filter maintenance
can cause poor performance.
NOTICE
Improper installation of the air filter assembly
cam/may allow dirt to enter the engine and
cause rapid wear of the piston rings and cylinder.
30
BASIC MAINTENANCE PROCEDURES
THROTTLE
THROTTLE FREEPLAY
+ A. Throttle free-play should be 3 – 5 mm (0.10 – 0.20 in)
B B. If your throttle has more play than specified,
C
adjustments need to be made. Follow the steps below:
C. Minor adjustments are generally made with the upper
_
adjuster.
A 1. Pull back the dust cover A .
2. Loosen the lock nut C
3. Turn the adjuster B
4. Turning the adjuster in the + direction will decrease
free-play. Turning the adjuster in the _ direction 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. Inspect the condition of the throttle cable from the
throttle down to the carburetor. If the cable is kinked
or chafed, it must be replaced.
7. Lubricate the cable with a commercially available
cable lubricant to prevent premature rust and/or
corrosion.
8. Check the cable for tension or stress in all steering
positions.
31
BASIC MAINTENANCE PROCEDURES
32
BASIC MAINTENANCE PROCEDURES
CLUTCH SYSTEM
In order to ensure the best performance and durability from the clutch, always be sure you have proper
clutch free-play. Free-play is needed to ensure that the clutch has room for wear. A clutch with no free-play
will begin to slip as the discs wear down. Failure to fix a slipping clutch can cause clutch damage. To check
the free-play, simply pull on the clutch lever. The lever should move very easily within the free-play range
before you feel the clutch begin to engage. If too much or too little free-play exists, adjustments are needed.
A second adjustment may be needed if the clutch is slipping or if the clutch will not engage. Follow the
steps below carefully to perform the adjustment. If the clutch is slipping, you will need to decrease the
amount of clutch engagement. If you squeeze the clutch lever all the way and the clutch still will not engage,
you need to increase the engagement. (Clutch Free-play 10 – 15 mm)
33
BASIC MAINTENANCE PROCEDURES
XZ250R - ZS
A B
XZ250R V4
34
BASIC MAINTENANCE PROCEDURES
SPARK PLUG
The recommended standard spark plug will work very well in most riding condition. However, if you plan
on riding for extended periods of time at high speed or high engine rpm in hot climates, or plan extended
riding in cold climates, a different plug may be recommended.
A fouled (dirty) spark plug can cause your motorcycle to run poorly and lose performance. Follow the steps
below to inspect, clean and/or replace the spark plug if needed.
1. Clean any dust and dirt from around the spark plug base.
2. Disconnect the spark plug cap.
3. Remove the spark plug.
4. Using the photos below for reference, examine the plug to determine its cleanliness. If the plug is a
normal color, go on to step 6. If the plug is fouled (dirty), go to step 5.
5. Using moderate grit sandpaper (220-400), sand between the center electrode and the side electrode until
all carbon and oil deposits are removed. Crossfire recommends that you use a spark plug cleaner or a new
spark plug if the plug is very dirty.
6. Inspect the spark plug electrodes for wear. The center electrode should have square edges. The side
electrode should not be eroded at all. The insulator should not be cracked or chipped. Replace the plug if
any electrode wear and/or cracks are present.
7. Check the spark plug gap using a spark plug gaper. Gapers can be purchased at your local auto parts 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 hand. This will prevent
stripping and/or cross threading of the threads. Use a 5/8 in socket or wrench to securely tighten the spark
plug. Do not over or under tighten the spark plug.
When you inspect the spark plug, generally it will fit into one of the four categories shown above. A normal/clean
spark plug will have a light brown center and displays no wear around the electrodes. A spark plug with a bright white
center indicates a lean condition in the engine. If your plug looks like this, have your motorcycle serviced by your
Crossfire dealer immediately. A carbon fouled plug will be completely black with no gloss. An oil fouled plug will
appear a dark shiny brown or shiny black as shown above. An oil fouled plug is caused when the engine oil seeps by
the piston ring and is burned with the fuel. Oil fouled plugs are not uncommon, however, if your motorcycle is
consistently oil fouling spark plugs, have it serviced by your local Crossfire dealer immediately.
NOTICE NOTICE
Using a spark plug with an improper heat range or An improperly tightened spark plug can damage the
incorrect reach, can cause engine damage. Using a engine. If a plug is too loose, a piston may be damaged.
non-resistor spark plug may cause ignition problems. If a plug is too tight, the threads may be damaged.
35
BASIC MAINTENANCE PROCEDURES
BRAKEING SYSTEM
Your motorcycle is equipped with hydraulic disc brakes on both the front and rear wheels. Hydraulic brakes
require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the
master cylinders. Follow the procedures below to adjust the brake levers to the specified ranges and check
fluid levels.
36
BASIC MAINTENANCE PROCEDURES
If you are unsure how to re-assemble a part, contact your Crossfire dealer for servicing information and/or
servicing.
NOTICE
Be very careful not to spill brake fluid on painted
surfaces or it will damage the paint. It will also be
harmful to some rubber parts. Be careful when you
remove the master cylinder cap, make sure the
motorcycle is in an upright position.
37
BASIC MAINTENANCE PROCEDURES
38
BASIC MAINTENANCE PROCEDURES
FRONT SUSPENSION
Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle.
If any of the suspension components seem to be worn or damaged, see your Crossfire dealer for service
and/or inspection. Your Crossfire dealer is the most qualified to determine whether 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.
39
BASIC MAINTENANCE PROCEDURES
FRONT SUSPENSION
REAR SUSPENSION
Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle.
If any of the suspension components seem to be worn or damaged, see your Crossfire dealer for service
and/or inspection. Your Crossfire dealer is the most qualified to determine whether 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.
Push From Here
NOTICE
DO NOT TRY TO REPAIR THE SHOCK.
IF REPAIR IS NECESSARY, TAKE THE
MOTORCYCLE TO A CROSSFIRE DEALER.
40
BASIC MAINTENANCE PROCEDURES
The rear suspension of your motorcycle has 3 different adjustment points. It comes from the factory set to
the softest setting. If you wish to make the rear suspension harder, follow the procedure below. Adjusting
the rear shock is not hard, but like the front forks, changes should be made one at a time to gain an accurate
understanding of how they affect the bike.
Once you are familiar with the settings on your suspension, you can quickly and easily adjust them to suit
different terrain. For example, you make know the setting position for when you ride in the sand dunes. But
when you are riding on your local motocross track you know to tune them to a different setting.
D
_
1. Both the high and low speed damping can be increased by turning the appropriate adjuster clockwise.
2. Adjust the high speed adjuster in 1/12th turn increments.
3. The first thing we‟ll look at is the high-speed compression adjuster. Using a wrench, turn the nut C
clockwise 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 C can help make the bike ride more smoothly over choppy land.
5. The low-speed compression adjuster D can be turned clockwise to make the overall feel of the shock
firmer. Or, turn it counter-clockwise to soften it. Your preferred settings will depend on what style of
riding you do. If you prefer riding trails then you may want to set it towards soft. If you are on high
jumps and whoops, you will definitely want to make it harder. Remember, having the screw turned all the
way too hard puts more pressure on the shock, so keep it a few clicks out.
6. Next, you‟ll find the rebound adjuster at the bottom of the shock under the swing-arm. This works much
the same as the rebound screw on the front forks. It controls how quickly or slowly the shock returns to
its extended position after being compressed.
7. Try turning it clockwise to allow the rear wheel to stay in contact with the ground over larger rolling
terrain.
8. If you turn the screw counter-clockwise this should give you a better ride over rough bumps that are close
together by allowing the shock to rebound faster and „hug‟ the flow of the terrain.
41
BASIC MAINTENANCE PROCEDURES
42
BASIC MAINTENANCE PROCEDURES
TIRE PRESSURE
Front Tire 20 Psi (138 kPa)
WARNING
USING TIRES THAT ARE EXCESSIVELY WORN OR
IMPROPERLY INFLATED CAN CAUSE A CRASH IN
WHICH YOU CAN BE SERIOUSLY INJURED OR
KILLED. FOLLOW ALL INSTRUCTIONS IN THIS
OWNER’S MANUAL REGARDING TIRE INFLATION
AND MAINTENANCE.
43
BASIC MAINTENANCE PROCEDURES
TIRE INSPECTION
A flat tire or tire blowout can be very inconvenient and can even cause you to have an accident. Take the
time to inspect your tires and wheels before you ride. For more information about handling a flat tire, refer
to the section of this manual titled, Resolving the Unexpected.
Inspect the tire carefully for bumps or bulges in the sidewall of the tire and inside of the treads.
replace any tires that have bumps or bulges in them.
Look closely for cuts, slits or cracks in the tires. Replace any tire if you can see a fabric or cord showing
through.
Check for rocks or other objects embedded in the tires or tread. Remove any foreign objects. Be sure
there are no screws or nails in the tires.
Measure the tread depth of the tires. Replace all tires before the read depth gets below 0.12in (3mm) or
anytime you notice a reduction in your traction.
Check the position of both valve stems. A tilted valve stem indicates that the tube is slipping inside of
the tire or the tire is slipping on the rim. See your Crossfire dealer for assistance.
TIRE SIZE
Front Tire 80/100-21
Rear Tire 110/100-18
WARNING
Type Bias Ply, Tube Type
INSTALLING IMPROPER TIRE ON YOUR MOTORCYCLE
CAN AFFECT HANDLING AND STABILITY. WHICH, IF
SEVERE, CAN CAUSE A CRASH IN WHICH YOU CAN BE
SERIOUSLY HURT OR KILLED. ALWAYS USE THE SIZE
AND TYPE OF TIRES RECOMMENDED IN THIS OWNER’S
MANUAL.
44
BASIC MAINTENANCE PROCEDURES
DRIVE CHAIN
The service life of your drive chain will depend on several factors including proper lubrication, adjustment,
and riding style. If you are an experienced rider and tend to ride in a more intense manner, or you ride in
muddy/dusty areas, you will need to check the drive chain more frequently. Poor maintenance will cause
pre-mature wear and/or damage to the drive chain and sprockets.
Before you service your drive chain, be sure you are parked on a level surface and you turn the engine OFF.
Be sure the transmission is in neutral. It is not necessary to remove or replace the chain to perform
recommended maintenance service.
CHAIN INSPECTION
3. Inspect the drive chain for the following: damaged rollers, loose pins, dry or rusted links, kinked or
binding links and excessive wear. Replace the chain, loose pins, or kinks that cannot be freed. Lubricate
the drive chain if it appears dry or shows signs of rust. Lubricate any kinked or binding links and work
them free.
4. You should replace the drive chain once the rear axle is moved as far back as possible and slack still
remains. This indicates that the chain is worn beyond its service limit.
5. Inspect the front and rear sprockets for excessive wear or damage. Refer to the illustration at the top of
page 42. If needed, replace any worn or damaged sprockets. See your Crossfire dealer for assistance.
NOTICE
EXCESSIVE DRIVE CHAIN SLACK MAY
ALLOW THE DRIVE CHAIN TO DAMAGE
THE ENGINE CASES..
NOTICE
ALWAYS USE HIGH QUALITY LUBRICANT
FOR THE DRIVE CHAIN.
45
BASIC MAINTENANCE PROCEDURES
Use the diagram below to determine if the sprockets need to be replaced. Never use a new chain with a
damaged or worn sprocket.
NOTICE
THE USE OF A NEW CHAIN ON A WORN
SPROCKET WILL CAUSE RAPID CHAIN
WEAR.
CHAIN ROLLERS
CAUTION
NEVER RIDE YOUR MOTORCYCLE IF THE
ROLLERS ARE WORN EXCESSIVELY.
Fig. 1
NOTICE
ALWAYS USE HIGH QUALITY LUBRICANT
FOR THE DRIVE CHAIN.
46
BASIC MAINTENANCE PROCEDURES
CHAIN SLIDERS
Fig. 1
Fig. 2
Fig. 3
NOTICE
THE SLIDERS MUST BE REPLACED IF
WORN DOWN TOO FAR.
47
BASIC MAINTENANCE PROCEDURES
CHAIN ADJUSTMENT
Follow the procedure below to adjust the drive chain slack. Be sure that you are parked on a level surface
and the engine is turned OFF.
E D CHAIN ADJUSTMENT
1. Loosen the rear axle nut A
2. Loosen the lock nut B on both right and left side.
3. Turn the adjusting bolts C counter-clockwise to
decrease slack in the chain, or clockwise to increase
B slack.
A
4. Align the marks 1 in Fig. 1 of the adjusting plate D
C
with the same reference marks E on both sides of the
swing-arm.
5. Tighten the axle nut A to 85ft-lbs. (115 Nm)
6. Re-check chain slack and readjust if necessary.
Fig. 1
CHAIN LUBRICATION
48
BASIC MAINTENANCE PROCEDURES
The master 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 chain.
You may find it easier to install a new chain by connecting it to the old chain using a master link and pulling
the old chain to position the new chain on the sprockets.
APPEARANCE CARE.
To clean the motorcycle you can use any of the following: water, mild neutral detergents, mild spray and
wipe cleaner, mild spray and rinse cleaner/degreaser. Avoid products that contain harsh detergents or
chemical solvents that can damage the metal, paint and plastic on your motorcycle.
We recommend that you use a garden hose to wash your motorcycle. High pressure washers (like coin
operated car washers) can damage certain parts of the motorcycle. If you must use a high pressure washer,
avoid spraying the following areas: Wheel hubs, muffler outlet, underneath the seat, engine stop switch,
underneath the gas tank, drive chain and carburetor.
NOTICE
HIGH PRESSURE WATER OR AIR CAN DAMAGE CERTAIN
PARTS OF THE MOTORCYCLE. NEVER WAS THE
MOTORCYCLE WHILE THE ENGINE IS RUNNING. ALWAYS
LUBRICATE THE DRIVE CHAIN AFTER YOU ARE FINISHED
WASHING AND THE MOTORCYCLE IS DRY.
49
TROUBLESHOOTING
2. Examine the Spark Plug - Remove the spark plug and inspect. (see page 31)
Is the spark plug in good working condition?
No - Flooded engine and/or carburetor
- Choke valve is closed
- Throttle is stuck open
- Dirty or clogged air filter
- Excessively worn piston rings (replace engine)
Yes - SEE STEP 3
3. Spark Test - Test for ignition spark by removing the spark plug and inserting it into the spark plug cap. Place the open end of
the spark plug on a metal part of the engine and kick start the engine. You should see a nice blue spark on the end of the spark
plug. A faint spark will not start the engine.
Is there a good spark?
No - Fouled or faulty spark plug NOTICE
- Broken or shorted spark plug wire or spark plug cap DO NOT TOUCH THE SPARK PLUG OR PLUG CAP
- Broken or shorted ignition coil WHILE TRYING TO START THE ENGINE. YOU WILL
- Faulty ignition CDI Box RECEIVE AND ELECTRICAL SHOCK WHICH COULD
- Faulty or shorted magneto assembly RESULT IN SERIOUS INJURY OR DEATH.
- Broken or shorted engine stop switch
- 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 sure you have the
spark plug installed. While pushing down on the kick starter slowly, you should feel a very hard firmness that will abruptly soften
as the kick start lever moves further down. No hard firmness in the kick start lever means you have poor compression.
Is the compression normal?
No - Valve stuck open/seized or improper valve timing (see your Crossfire dealer)
- Worn cylinder wall and/or piston rings (replace engine)
- Leaking or damaged cylinder head gasket (see your Crossfire dealer)
Yes - SEE STEP 5
5. Engine Start Condition - Start the engine by using the normal starting procedure (see page 15,16)
Does the engine start but then stop quickly afterward?
Yes - Improper choke operation
- Dirty or improperly adjusted carburetor (Contact your Crossfire Dealer)
- Intake manifold/pipe leak
- Improper ignition timing (see your Crossfire Dealer)
- Dirty or contaminated gasoline
50
TROUBLESHOOTING
2. Check the Tire Pressure - Use a tire pressure gauge to check the tire pressure of each tire (see page 29)
Is the tire pressure correct?
No - Faulty tire valve
- Punctured tire and/or inner tube
Yes - SEE STEP 3
5. Spark Plug inspection - Remove the spark plug and inspect (see page 23)
Is the spark plug in good working condition?
No - Spark plug is not serviced frequently enough
- Incorrect spark plug heat range (see page 23)
- Incorrect spark plug gap
Yes - SEE STEP 6
6. Engine Oil Inspection - Check the oil level and the condition of the oil
Is the engine oil level correct and in clean condition?
No - Oil level too high
- Oil level too low
- Contaminated oil
Yes - SEE STEP 7
51
TROUBLESHOOTING
10. Engine Condition Inspection - Accelerate rapidly through all gears and ride at high speed.
Does the engine knock?
No - SEE STEP 11
Yes - Worn piston and cylinder (replace engine)
- Wrong type of fuel (octane rating)
- Lean fuel mixture
- Excessive carbon buildup in the combustion chamber
11. Ignition Timing Inspection - 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 tools needed.
Is the ignition timing normal? (Timing is non-adjustable)
No - Faulty CDI ignition box
- Faulty ignition pulse generator
Yes - SEE STEP 12
12. Lubrication Inspection - Remove the valve adjuster hole cap on the cylinder head and inspect for lubrication.
Is the valve train lubricated properly?
No - Clogged oil passage (replace engine)
- Dirty and/or contaminated engine oil
Yes - See your Crossfire dealer to have your motorcycle serviced.
52
TROUBLESHOOTING
3. Carburetor Air Screw Inspection - Check the carburetor air screw. Turn the screw clockwise until you feel it stop. Do not
tighten. Back out the screw counter clockwise 1.5 turns.
Is the air screw setting correct?
No - Adjust using the procedure above.
Yes - SEE STEP 4
4. Ignition Timing Inspection - See your local Crossfire dealer or motorcycle repair shop to have the ignition timing inspected.
Only attempt these procedures if you are qualified and have the proper tools needed.
Is the 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
3. Ignition Timing & Valve train Inspection - See your local Crossfire dealer or motorcycle repair shop to have the ignition
timing inspected. Only attempt these procedures if you are qualified and have the proper tools needed.
Are the ignition timing, valve timing and valve springs normal? (Timing is non-adjustable)
No - Faulty CDI ignition box
- Faulty ignition pulse generator
- Broken valve spring
- Broken or damaged camshaft sprocket
Yes - See your Crossfire dealer to have your motorcycle serviced
53
TROUBLESHOOTING
POOR HANDLING
Steering is heavy
- Steering stem nut too tight
- Damaged steering head bearings
- Check tire pressure
Either wheel has a Wobble
- Excessive wheel bearing 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
- Faulty shock absorber
- Damaged fork(s)
- Bent Swing-arm
- Damaged axel
- Damaged frame
- Damaged upper or lower triple clamp
54
RESOLVING THE UNEXPECTED
GENERAL GUIDELINES
If you encounter trouble during a ride, the first thing you should do is stop as soon as it is safely possible.
Do not continue to ride if you have a flat tire, if you hear an unusual noise, or if your motorcycle just does
not feel right. If you continue to ride, you will cause more damage the motorcycle and endanger your own
safety.
After you stop, take time to carefully look over your motorcycle and identify the problem. Always consider
all of your options before you make a decision. Sometimes a problem can be relatively minor and can be
permanently repaired on the trail provided you have the tools, supplies and skills needed to do so. In
addition, you may be able to make a temporary repair and ride slowly back to your base where you can get
further help and/or supplies.
When a problem appears to be more serious; or you do not have the tools, supplies and skills needed to
make a repair, you will need to choose a safe way to get yourself and the motorcycle back to your base. If
you are close enough, you can often push the motorcycle back.
Whatever the problem may be, always follow the instructions below:
1. Always put safety first.
2. If the problem is minor and you have the tools, supplies and skills needed to make a temporary repair, be
sure to make permanent repairs as soon as possible.
3. Do not continue riding if you are hurt or if your motorcycle is not in safe riding condition.
Recommendations for specific problems follow.
1. Make sure you have fuel in the gas tank and the fuel valve is set to the “ON” position.
2. Check the fuel tank cap breather hose to be sure it is not pinched or clogged.
3. Turn the fuel valve to the “OFF” position. Disconnect the fuel line from the carburetor and momentarily
turn the fuel valve to “ON”. If fuel does not flow out, there is an obstruction in the fuel tank, fuel filter, or in
the fuel line.
If the fuel system appears to be okay, check the ignition system.
1. Check the spark plug cap. Be sure that it is not loose or disconnected.
2. Disconnect the spark plug cap and remove the spark plug. Connect the spark plug to the plug cap and
place the threaded end of the spark plug on a metal part of the engine.
3. Kick the kick starter while you watch the spark plug. If it sparks, the ignition system is probably working.
If there is no spark, replace the spark plug with a new one. If there is still no spark, there is a problem with
the ignition system.
If you cannot identify or correct a problem, you will have to push your motorcycle back to your base or get
some help.
55
RESOLVING THE UNEXPECTED
IF YOU CRASH
Personal safety is the first priority after an accident. If you or anyone else has been injured, take plenty of time to
assess the severity of the injuries and determine if it is safe to continue riding. If you cannot ride safely, send
someone for help. Do not ride if you will risk further injury or if your motorcycle has been damaged too severely.
If you decide you are capable of riding safely, carefully inspect the motorcycle for damage. Check the tightness
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, ride slowly and cautiously.
Sometimes crash damage is hidden or not immediately apparent. Once you get home, go over your motorcycle
thoroughly and fix any problems that you find. Also, be sure to have your Crossfire dealer inspect the frame and
suspension after a serious crash.
IF A COMPONENT FAILS
The drive chain, master link, control cables, brake controls, and other components can be damaged if you ride in
dense brush or over rocky terrain. As mentioned earlier, making the repair on the trail will depend on the severity
of the damage, tools, supplies, and skills that you have.
1. If the drive chain comes off because the master link clip has been knocked off, you may be able to repair the
chain with a new master link. However, if the chain is broken or causes damage when it comes off, you may not
be able to make a trailside repair.
2. If any component of the front braking system is damaged, you may be able to ride back to your base carefully
using the rear brake for slowing and stopping. Likewise, if a component of the rear braking system fails, you can
use the front brake for slowing and stopping.
3. If you damage the throttle cable or some other critical component, the motorcycle may be unsafe to ride.
Carefully assess the damage and make any repairs that you can. But if you have any doubts, it is best to be
conservative and safe.
56
TORQUE SPECIFICATIONS
K
J
L
G
E
A
H
A F
B
C
D
Z
N
AA
Y
Q
S
U
V T
W
P
O
Q
AB
A1
AF
AC
AE
AH
G AK
AJ
D
AD
AL
AY
AM
AN
AQ
AO
AW AV
AX AU
AP AT
AS AR
57
TORQUE SPECIFICATIONS
Torque Torque
Name Notes Name Notes
N•m ft•lbs N•m ft•lbs
A Seat bolts 24.4 18 3 AA Brake hose bolt 32.4 24
B Brake hose bolt 32.5 24 AB Brake reservoir cap 2 1.5
C Exhaust mounting bolt 24.4 18 3 AC Triple clamp (upper) 21 15 2
D Sub-frame bolt (upper) 33.8 25 2 AD Triple clamp (lower) 21 15 2
E Shock spring lock nut 46 34 AE Handlebar riser (lower) 37.8 28 2
F Shock nut 47.4 35 3 AF Handlebar riser (upper) 27 20 3
G Sub-frame bolt (lower) 29.8 22 AH Exhaust cover bolt 6.7 5
H Shroud bolts 4.7 3.5 AJ Muffler clamp (LT / RT) 23 17
J Master cylinder holder 10 7.5 AK Muffler mount (LT / RT) 27 20 3
K Brake reservoir cap bolt 1.3 1 AL Chain roller bolt (TP/BT) 13.5 10 2
L Brake hose bolt 32.5 24 AM Brake caliper bolts 27 20 3
M Fender bolts 6.7 5 3 AN Shroud bolts 6.7 5
N Axle pinch bolts 23 17 3 AO Brake hose bolt 32.5 24
O Axle nut 81 60 3 AP Brake disc bolts 14.8 11 2
P Fork guard bolts 6.7 5 3 AQ Disc cover bolts 6.7 5 3
Q Rim lock 13.5 10 2 AR Drive sprocket bolts 37.8 28 2
R Engine mounting bolt 51.3 38 3 AS Chain adjuster nut 27 20
S Exhaust joint clamp 24.4 18 AT Chain guide bolts 6.7 5 3
T Engine mount (upper) 54 40 2 AU Connecting rod (rear) 60.7 45 2
U Kick starter bolt 33.7 25 2 AV Shock mount (lower) 48.6 36 2
V Brake lever pivot bolt 29.7 22 2 AW Kick stand bolt 40.5 30 3
W Brake lever adjuster nut 5.4 4 AX Connecting rod (front) 60.7 45 2
X Axle nut 121.5 90 2 AY Linkage connection 64.8 48 2
Y Brake disc bolts 17.5 13 2
Z Brake caliper bolts 27 20 3
A1 Steering stem nut ??
Notes:
1. Apply oil to threads.
2. Apply lock-tite liquid to threads. (Red)
3. Apply lock-tite liquid to threads. (Blue)
4. Apply grease.
58
TORQUE SPECIFICATIONS
XZ250R - LC
N D
Torque
A Name Notes
N•m ft•lbs
A Engine, Front 35 26
C B Oil Drain Cap 17.5 13
E C Engine mount (lower) 40.5 30
B
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 Starter 33.7 25
K Exhaust 20.2 15
L Water Pump 9.4 7
M Oil Filter 10.8 8
N Starter Gear Cover 9.4 7
Notes
F K 1. Apply oil to threads.
2. Apply lock-tite liquid to threads. (Red)
L 3. Apply lock-tite liquid to threads. (Blue)
4. Apply grease.
J
H
59
TORQUE SPECIFICATIONS
XZ250R - ZS
N D
A C Torque
Name Notes
N•m ft•lbs
A Engine, Front 35 26
E B Oil Drain Bolt 17.5 13
B
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 25
K Exhaust nut 20.2 15
L Oil Filter 10.8 8
M Water Pump 9.4 7
G N Starter Gear Cover 9.4 7
K P Clutch Cover 9.4 7
F
Notes
L
1. Apply oil to the threads.
2. Apply lock-tite to the threads. (Red)
3. Apply lock-tite to the threads. (Blue)
P
4. Apply grease.
J
H M
60
TORQUE SPECIFICATIONS
XZ250R – V4
A B
E
D
Torque
Name Notes
N•m ft•lbs
A Engine mount (top) 35 26 3
J B DO NOT REMOVE //// //// ////
C Engine mount (upper) 40.5 30 3
F D Sprocket cover bolts 16.2 12
E Sprocket bolt 48.6 36 2
G H 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 starter bolt 27 20 2
L Clutch cover bolts 10.8 8
M Oil filter bolts 10.8 8
N Oil filter screen 13.5 10
O Water pump 9.4 7 3
P Exhaust nut 20.2 15 2
P
Notes:
1. Apply oil to threads.
2. Apply lock-tite liquid to threads. (Red)
L
3. Apply lock-tite liquid to threads. (Blue)
4. Apply grease.
M N
61
SPECIFICATIONS
62
SPECIFICATIONS
63
MAINTENANCE SCHEDULE RECORD
00,000 km km km
hr. hr. hr.
km km km
hr. hr. hr.
km km km
hr. hr. hr.
NOTICE
THE FIRST OIL CHANGE MUST BE DONE BEFORE THE FIRST INITIAL RIDE.
64
NOTES
65
NOTES
66