Kawasaki KLX250-D1 1993 Werkstatthandbuch für Reparaturen

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 Variant: KLX250-D1 Year: 1993 Codes Chassis Code: D1 Engine Code Prefix: KL250DE 👋 Introduction Market Position Segment: Dual-sport/Enduro motorcycle, known for its...

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Art.-Nr: 603435

Stichworte: 1993 Kawasaki KLX Series KLX250-D1 Motorcycle Motorcycles

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Beschreibung

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250

Variant:

KLX250-D1

Year:

Codes

Chassis Code:

Engine Code Prefix:

KL250DE

👋 Introduction

Market Position

Segment:

Dual-sport/Enduro motorcycle, known for its versatility on and off-road.

Competitive Analysis

Competitors 1993:

Honda XR250L, Yamaha XT250, Suzuki DR250SE.

Key Features

Engine Type:

Liquid-cooled, four-valve, DOHC, single-cylinder engine.

Suspension Type:

Long-travel front forks and rear monoshock suspension for off-road capability.

Cooling System:

Liquid cooling for consistent engine performance under demanding conditions.

Transmission:

Six-speed gearbox offering a wide range of ratios for various terrains.

Braking:

Disc brakes front and rear for effective stopping power.

📋 Manual Details

Coverage Areas

Coverage:

Comprehensive repair and service procedures for the 1993 Kawasaki KLX250-D1.

Page Count

Pages:

Approximately 300-400 (estimated, as exact page count not specified in product info).

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Likely a printed manual or a high-quality digital reproduction (e.g., PDF).

📖 Manual Coverage

Systems Covered

Engine System:

Detailed breakdown of the 249cc liquid-cooled, four-stroke, single-cylinder engine, including disassembly, assembly, inspection, and repair of all internal components.

Fuel System:

Carburetor (likely Keihin CVK type) servicing, adjustment, troubleshooting, and overhaul; fuel tank and petcock inspection and repair.

Ignition System:

CDI ignition system inspection, testing of ignition coil, spark plug, and stator.

Cooling System:

Radiator, coolant hoses, water pump, and thermostat inspection, testing, and replacement procedures.

Exhaust System:

Exhaust pipe and muffler inspection, repair, and replacement.

Transmission System:

Six-speed sequential gearbox: disassembly, assembly, inspection of gears, shift drum, and shift forks; clutch operation and servicing.

Drivetrain System:

Final drive chain and sprocket inspection, adjustment, and replacement; rear hub and wheel bearing service.

Suspension System:

Front telescopic forks (likely Kayaba or similar) service: oil replacement, seal replacement, spring inspection; rear monoshock absorber service and linkage maintenance.

Braking System:

Front and rear disc brake systems: caliper overhaul, pad replacement, rotor inspection, brake fluid replacement, and bleeding procedures.

Wheel And Tire System:

Wheel bearing service, spoke inspection and tensioning, tire pressure checks, and mounting instructions.

Electrical System:

Wiring diagrams, lighting system (headlight, taillight, turn signals), battery service, charging system (stator and regulator/rectifier), and starter motor operation.

Frame And Bodywork:

Frame inspection, swingarm service, fuel tank removal/installation, seat, fenders, and fairing component repair and replacement.

Procedures Included

Maintenance Procedures:

Scheduled maintenance intervals, oil and filter changes, spark plug checks, air filter cleaning/replacement, chain lubrication and adjustment.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon issues, fault finding charts, and symptom-based troubleshooting.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Rebuild Procedures:

Complete engine and transmission rebuild instructions, including torque specifications and clearances.

Adjustment Procedures:

Carburetor idle speed and mixture, clutch lever free play, brake lever free play, chain slack, and suspension sag.

Wiring Diagrams:

Detailed electrical system wiring schematics for easy diagnosis and repair.

Torque Specifications:

Precise torque values for all fasteners and critical components.

Technical Depth

Depth:

In-depth coverage suitable for experienced DIY mechanics and professional technicians.

Diagnostic Capabilities:

Advanced diagnostic routines for identifying root causes of performance issues or failures.

Rebuild Level:

Full engine and transmission rebuild specifications and procedures.

📊 Manual Specifications

File Format

Digital Format:

If digital, typically PDF with searchable text and high-resolution images/diagrams.

Print Quality

Print Quality:

High-quality print for clear diagrams, illustrations, and text reproduction if it's a physical manual.

Binding Type

Binding:

If printed, typically spiral-bound or saddle-stitched for easy page lay-flat during work.

Paper Type

Paper Type:

If printed, usually durable, semi-gloss paper to withstand workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, single-cylinder.

Displacement:

249 cc (249 cm³).

Bore X Stroke:

72.0 mm x 61.2 mm.

Compression Ratio:

9.3:1.

Valve Train:

DOHC, 4 valves.

Fueling:

Carburetor (likely Keihin CVK34).

Ignition:

CDI (Capacitor Discharge Ignition).

Performance

Horsepower Approximate:

Approx. 28-30 HP @ 7500 RPM (manufacturer data not definitively available for this specific model year).

Torque Approximate:

Approx. 20-22 lb-ft @ 6000 RPM (manufacturer data not definitively available for this specific model year).

Fuel System

Carburetor Model:

Keihin CVK34 (typical for this era).

Fuel Tank Capacity:

Approximately 10.7 liters (2.8 US gallons).

Oil Capacity

Oil Capacity With Filter Change:

Approximately 1.7 liters (1.8 US qt) (check manual for exact specification).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh, sequential gearbox.

Clutch Type:

Wet, multi-disc.

Features

Gear Ratios:

Specific gear ratios are detailed within the workshop manual for each gear.

Final Drive:

Chain drive.

Fluid Specification

Transmission Oil Type:

API SE or SF, SAE 10W-40 motorcycle gear oil. (Verify with manual).

📐 Dimensions

Exterior

Length:

Approx. 2180 mm (85.8 in).

Width:

Approx. 800 mm (31.5 in).

Height:

Approx. 1205 mm (47.4 in).

Wheelbase:

Approx. 1430 mm (56.3 in).

Ground Clearance:

Approx. 255 mm (10.0 in).

Weights

Dry Weight:

Approx. 117 kg (258 lbs).

Curb Weight:

Approx. 130 kg (287 lbs) (estimated with fluids).

Suspension Travel

Front Suspension Travel:

275 mm (10.8 in).

Rear Suspension Travel:

265 mm (10.4 in).

🛡️ Safety Features

Ratings

Safety Ratings:

Motorcycles of this era were not subject to standardized crash testing like automobiles. Safety is primarily defined by rider control and braking effectiveness.

Active Features

Braking System:

Hydraulic disc brakes front and rear provide effective stopping power.

Suspension Geometry:

Long-travel, adjustable suspension contributes to stability and control over varied terrain.

Passive Features

Lighting:

Headlight, taillight, and brake light for visibility.

Chassis Design:

Strong, rigid frame designed to handle off-road stresses.

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation: speedometer, odometer, trip meter, and indicator lights. No advanced infotainment features.

Driver Assistance

Assistance Features:

No electronic rider aids like ABS or traction control. Relies on rider skill and mechanical systems.

Connectivity

Connectivity Options:

None. This is a 1993 model motorcycle with purely mechanical and basic electrical systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (1,800 miles) or 6 months (check manual for precise interval).

Air Filter Cleaning:

Every 1,000 km (600 miles) or as needed depending on riding conditions (check manual).

Spark Plug Check:

Every 3,000 km (1,800 miles) (check manual for exact interval and gap).

Chain Adjustment:

Every 1,000 km (600 miles) or as needed to maintain proper slack (check manual).

Fluid Specifications

Engine Oil Type:

API SE or SF, SAE 10W-40 motorcycle oil. (Verify with manual).

Coolant Type:

Permanent type coolant (ethylene glycol based) mixed with distilled water in a 50:50 ratio. (Verify with manual).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. (Verify with manual).

Known Issues

Carburetor Stalling:

Potential for fuel mixture issues or vacuum leaks causing rough idling or stalling, especially with age. Requires careful cleaning and adjustment.

Suspension Seals:

Worn fork seals can lead to oil leaks. Regular inspection and replacement is recommended.

Clutch Slippage:

With high mileage or aggressive use, clutch plates may wear, leading to slippage. Requires clutch pack replacement.

Electrical Connections:

Corroded or loose electrical connections can cause intermittent issues with lights or starting. Regular inspection and dielectric grease application is beneficial.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries has a long-standing reputation for producing high-performance motorcycles, including a strong lineage in off-road and dual-sport models.

Model Evolution

Klx Lineage:

The KLX series has been a cornerstone of Kawasaki's dual-sport offerings, evolving from earlier models like the KLR250 with a focus on enhanced off-road performance, especially in the KLX designation.

Production

Klx250 Production Years:

The KLX250 line has seen various iterations and has been in continuous or intermittent production across different markets for many years, with the D1 representing a specific iteration from the early 1990s.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for the 1993 KLX250-D1 are not widely documented, the KLX series has consistently been recognized for its reliability, off-road capability, and value in the dual-sport segment.

Ratings

Owner Satisfaction:

Generally positive owner feedback for its durability and performance for its class and era.