1987 Kawasaki Mojave 250 Service Manual

The 1987 Kawasaki Mojave 250 is a rugged all-terrain vehicle featuring a 249cc four-stroke single-cylinder engine, 5-speed transmission with reverse, shaft drive system, front and rear suspension, hydraulic disc brakes, and electric start. This service manual provides comprehensive technical information for maintenance, repair, and troubleshooting procedures. Below are key sections covering specifications, maintenance schedules, engine service, chassis, electrical systems, and troubleshooting.

General Information

Key components: 249cc 4-stroke engine, 5-speed transmission with reverse, shaft drive, front and rear suspension, hydraulic disc brakes.

Specifications

• Overall Length: 1,825 mm (71.9 in)
• Overall Width: 1,070 mm (42.1 in)
• Overall Height: 1,075 mm (42.3 in)
• Wheelbase: 1,220 mm (48.0 in)
• Ground Clearance: 170 mm (6.7 in)
• Seat Height: 785 mm (30.9 in)
• Dry Weight: 175 kg (386 lbs)
• Fuel Capacity: 7.5 liters (2.0 US gal)
• Oil Capacity: 1.5 liters (1.6 US qt)
• Tire Size Front: 21 x 7-10
• Tire Size Rear: 22 x 10-8

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

1. After first 20 hours/300 miles: Change engine oil and filter
2. Every 100 hours/1,500 miles: Check valve clearance
3. Every 200 hours/3,000 miles: Replace spark plug
4. Every 300 hours/4,500 miles: Clean air filter, check brake pads
5. Every 600 hours/9,000 miles: Change final drive oil
6. Monthly: Check tire pressure, brake fluid level

WARNING! Always perform maintenance on level ground with engine off and cool.

Engine Service

Engine maintenance procedures and specifications.

1. Valve Clearance: Intake: 0.10-0.15 mm, Exhaust: 0.15-0.20 mm
2. Spark Plug: NGK DR8ES-L, Gap: 0.7-0.8 mm
3. Oil Type: SAE 10W-40, API SE or higher
4. Idle Speed: 1,400 ± 100 rpm
5. Compression Pressure: 1,100 kPa (160 psi) minimum

CAUTION! Allow engine to cool before performing service work.

Fuel System

Carburetor specifications and maintenance.

1. Carburetor Type: Mikuni VM28SS
2. Main Jet: #130
3. Pilot Jet: #30
4. Needle Jet: O-8
5. Float Height: 21.0 mm
6. Fuel Filter: Clean every 200 hours

Tip: Use fresh fuel and stabilizer for extended storage.

Chassis & Suspension

Frame, suspension, and steering components.

1. Front Suspension Travel: 150 mm (5.9 in)
2. Rear Suspension Travel: 140 mm (5.5 in)
3. Front Wheel Alignment: Toe-in 0-10 mm
4. Steering Head Bearing: Adjust if loose
5. Swingarm Pivot: Check for play every 300 hours

WARNING! Always support vehicle properly when working on suspension.

Electrical System

Battery, charging system, and electrical components.

Transmission & Drive

Gear ratios and drive system specifications.

• Primary Reduction: 2.833 (68/24)
• Gear Ratios: 1st: 2.833, 2nd: 1.875, 3rd: 1.368, 4th: 1.095, 5th: 0.913
• Reverse Ratio: 3.666
• Final Reduction: 3.166 (38/12)
• Drive Shaft Oil: SAE 80W-90, 180 ml
• Clutch Type: Wet multi-plate

Brake System

Hydraulic brake specifications and maintenance.

1. Front Brake Disc Diameter: 186 mm
2. Rear Brake Disc Diameter: 186 mm
3. Brake Fluid: DOT 4
4. Brake Pad Thickness: Replace if less than 1.0 mm
5. Brake Lever Free Play: 10-20 mm

CAUTION! Use only specified brake fluid; avoid contamination.

Troubleshooting

Emergency Procedures: Always carry basic tools and first aid kit.

Service Support: Contact authorized Kawasaki dealer for technical assistance.