Product Name:
1993-1997 Kawasaki KLX250 KLX300 4 Stroke Motorcycle Service Manual
Covered Years:
1993, 1994, 1995, 1996, 1997
Chassis Codes Klx250:
KL250-D1 to KL250-D5 (typical for this era, exact codes may vary)
Chassis Codes Klx300:
KL300-A1 to KL300-A5 (typical for this era, exact codes may vary)
Target Audience:
Owners and technicians working on Kawasaki KLX250 and KLX300 models from 1993-1997, seeking detailed service and repair information.
Value Proposition:
Provides comprehensive, instant, and easily accessible digital repair information, eliminating the need for physical manuals prone to damage.
Delivery Method:
Instant downloadable PDF post-payment, ensuring immediate access.
Usability:
Designed for on-the-go troubleshooting via smartphones or easy printing of relevant pages.
Vendor Assurance:
GearHead Manuals is presented as the exclusive source for these specific downloads.
Geographic Coverage:
Global (based on standard Kawasaki service procedures)
Manual Types Covered:
Repair Manual, Service Manual, Workshop Manual, Owner's Manual, Parts Catalog (as indicated by seller)
Estimated Page Count:
Not specified, but typically 300-600 pages for a comprehensive service manual of this era.
Language:
English (implied by product description)
Delivery Format:
Downloadable PDF
File Format Details:
Plain simple easy to use PDFs only, no ZIP files or additional software required.
Engine:
Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components.
Fuel System:
Carburetor (model specific) service, adjustment, cleaning, and troubleshooting; fuel pump (if applicable), fuel lines, and fuel tank inspection.
Lubrication And Cooling:
Oil pump service, oil filter replacement, oil change procedures, cooling system (air-cooled or liquid-cooled depending on specific model variant) maintenance and inspection.
Transmission Drive:
Clutch operation, removal, and adjustment; gearbox inspection and repair; drive chain and sprocket inspection, adjustment, and replacement.
Steering Suspension:
Handlebar, steering stem, bearings, fork (front suspension) service, seal replacement, oil levels, and adjustment; rear shock absorber inspection, service, and linkage maintenance.
Electrical System:
Ignition system (CDI, stator, spark plug), lighting system, battery maintenance, charging system, wiring diagrams, and component testing.
Bodywork Frame:
Fender, seat, fuel tank, side panels, and fairings removal, installation, and minor repair; frame inspection for damage or alignment issues.
Intake Exhaust:
Airbox inspection and cleaning, air filter replacement, exhaust system inspection and repair, muffler maintenance.
Routine Maintenance:
Regular service checks, fluid level checks, lubrication points, filter replacements, and general upkeep.
Troubleshooting:
Advanced troubleshooting guides for common and complex issues, diagnostic procedures, and problem-solving techniques.
Engine Rebuild:
Step-by-step instructions for complete engine disassembly, component inspection, measurement, parts replacement, and reassembly.
Suspension Service:
Detailed procedures for fork seal replacement, oil changes, shock absorber service, and adjustment of suspension settings.
Electrical Diagnostics:
Testing of electrical components, troubleshooting wiring issues, and interpreting wiring diagrams.
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics.
Engine Type Klx250:
4-stroke, DOHC, single-cylinder
Engine Type Klx300:
4-stroke, DOHC, single-cylinder (derived from KLX250 with increased displacement)
Bore X Stroke Klx250:
Approximately 72.0 x 61.2 mm (typical for this generation, verify with manual)
Displacement Klx250:
249 cc (typical for this generation, verify with manual)
Bore X Stroke Klx300:
Approximately 78.0 x 61.2 mm (typical for this generation, verify with manual)
Displacement Klx300:
292 cc (typical for this generation, verify with manual)
Horsepower Klx250:
Approx. 28-30 HP at ~7000 RPM (varies by market and tuning, consult manual for exact specifications)
Torque Klx250:
Approx. 20-22 lb-ft at ~6000 RPM (varies by market and tuning, consult manual for exact specifications)
Horsepower Klx300:
Approx. 30-33 HP at ~7000 RPM (varies by market and tuning, consult manual for exact specifications)
Torque Klx300:
Approx. 22-24 lb-ft at ~6000 RPM (varies by market and tuning, consult manual for exact specifications)
Carburetor Type Klx250:
Keihin CVK34 (typical, verify with manual)
Carburetor Type Klx300:
Keihin CVK34 or similar enhanced version (typical, verify with manual)
Fuel Type:
Unleaded gasoline, Octane Rating: 87 or higher (check manual for specific recommendations)
Engine Oil Type:
API SG, SF or higher, SAE 10W-40 motorcycle oil recommended (verify specific viscosity and API rating in manual)
Oil Capacity With Filter:
Approx. 1.7 - 1.9 Liters (verify with manual)
Cooling Method:
Air-cooled (standard for these models, verify with manual)
Overall Length:
Varies by model, but typically around 2200-2300 mm (consult manual for precise figures)
Overall Width:
Varies by model, but typically around 800-850 mm (consult manual for precise figures)
Overall Height:
Varies by model, but typically around 1200-1250 mm (consult manual for precise figures)
Dry Weight Klx250:
Approx. 126 kg (verify with manual)
Dry Weight Klx300:
Approx. 128 kg (verify with manual)
Fuel Tank Capacity:
Approx. 10 - 12 Liters (verify with manual)
Crash Safety Standards:
N/A (Motorcycle safety ratings differ from automotive; focus is on structural integrity and rider protection features as per manual)
Braking System Front:
Disc brake, hydraulic (verify caliper type and disc diameter in manual)
Braking System Rear:
Disc brake, hydraulic (verify caliper type and disc diameter in manual)
Lighting:
Headlight, tail light, brake light, turn signals (functionality and maintenance covered in manual)
Oil Change Interval:
Typically every 3,000 - 6,000 km or 6-12 months (verify specific interval and conditions in manual)
Air Filter Cleaning:
Every 1,000 - 2,000 km or annually (verify in manual)
Spark Plug Replacement:
Typically every 6,000 - 10,000 km (verify in manual for specific plug type and gap)
Fork Oil Type:
SAE 10W (typical, but specific grade and quantity are critical and found in the manual)
Brake Fluid Type:
DOT 3 or DOT 4 (verify specific type and flush interval in manual)
Carburetor Performance:
Carburetors can become gummed up with age and infrequent use, requiring cleaning and adjustment. Jetting may need modification for aftermarket exhausts or high altitudes.
Suspension Wear:
Fork seals can degrade over time, leading to leaks. Shock absorbers may lose damping effectiveness.
Electrical Connections:
Corrosion on electrical connectors can cause intermittent issues with lights or ignition.
Cam Chain Tensioner:
Some owners report that the automatic cam chain tensioner can become weak over time, potentially leading to a rattling noise. Manual replacement may be recommended.
Kawasaki Offroad Legacy:
Kawasaki has a strong heritage in off-road motorcycles, with the KLX line evolving from earlier models to become a popular dual-sport and trail bike series.
Klx Series Development:
The KLX250 and KLX300 models of this era represent a period of refinement in Kawasaki's dual-sport offerings, balancing trail capability with on-road usability. The KLX300 was an enhancement to the KLX250 platform, offering increased displacement for more power.
Production Period:
1993-1997 for the specific variants covered by this manual.
