One nice thing that the supplement manual includes that the base manual does not is a wiring for our bike.

 

Would the 1993-1996 KLX250/R service manual be the same for the 2007 KLX250S then?

 

Well, my mother of all people decided to be nice and went to the Kawasaki dealer to order the service manual for me. Orignal cost was $61.15, but she some how got a discounted to $59.65. I'll find out this Thursday if it the right one, only comes in one book now. I'll be there tomorrow myself to look at the engine oils and to order some parts also.

 

Just got done with the valve adjustment. And I hate to say it, but none of them needed to be adjusted. All 4 valves were dead center of tolerence. And I still got that danm ticking noise. [:@]. The only thing I could figure would be left is the Exhuast valve releaser. The cam on that seemed really loose. So I'll be looking through the service manual for that.

In all, I got to see the KLX naked without the body panels. The bike is just do danm simple. Gotta love it thou.

 

Check the spring real closely on that "Exhaust valve releaser" (ACR).some times they wear thin and weaken or completely come out of the assembly. Also I'd like to echo what someone else said. The tensioner doesn't take really fine steps. Mytop-end will get noisey for awhile until that tensioner finally clicks to the next notch. I don't sweat it anymore.

 

humm.... I havent checked my valve clearences yet (5,000+miles) is this a horriable crime i've commited? did i hurt my baby?

 

You my friend get a cookie. Unbelievebly, after 130miles of driving Monday & Tuesday. Today when I started the KLX for the ride to work, it was the same old noise, then click, the engine went so much quiter. I think you hit iton the nail. It just takes some time for the tensioner to adjust. And it was the same coming back home, a lot quiter. But at least I know everything else is fine. I've also swithched the oil from Royal Purple Max-Cycle 10w-40 to Mobil 1 V-Twin 20w-50. There is hardly any retailers that sell Mobil 1 10w-40, and all of them were out of stock.

 

Great stuff!

I added this to the KLX FAQ list

 

Just finished reading this post.. took me an hour to go through all the pages and pictures.. wow.

So.. one question.
1. there was the one suggestion about a large magnet to keep the shim from dropping down. Are there any other methods of keeping that shim in place? this part has me pretty scared.

 

What should the clearance be?
I'm getting around 0.15 on Exhaust side (F) and 0.10 on Intake side (R).

Can any one state what the correct clearance tolerances should be for my bike? (see above).

I have my valve cover off and don't want to put it back on if I need to change the clearances now.

Cheers!