Engine Overhaul:
Comprehensive engine disassembly, inspection, repair, and reassembly procedures for the KLX 250 VC engine.
Fuel System:
Carburetor (Keihin CVK34) tuning, cleaning, and repair; fuel tank and pump inspection; fuel lines.
Ignition System:
Ignition coil, spark plug, CDI unit, timing checks and adjustments.
Cooling System:
Radiator, coolant hoses, water pump, thermostat maintenance and inspection.
Exhaust System:
Exhaust pipe and muffler removal, inspection, and installation.
Transmission And Clutch:
Clutch operation, adjustment, and replacement; gearbox disassembly, inspection, and reassembly; gear ratios.
Suspension:
Front fork (upside-down telescopic) disassembly, oil change, seal replacement, and damper adjustment; rear monoshock absorber inspection, service, and adjustment.
Brakes:
Front and rear disc brake system maintenance, caliper overhaul, pad replacement, fluid bleeding, master cylinder inspection.
Wheels And Tires:
Wheel bearing inspection and replacement, spoke tension adjustment, tire pressure and wear checks.
Electrical System:
Battery, charging system (stator, regulator/rectifier), lighting system (headlight, taillight, signals), starter motor, wiring diagrams, fuses.
Frame And Bodywork:
Frame inspection, handlebar, seat, fuel tank, fenders, and fairing removal and installation.
Chassis Components:
Swingarm, linkage (if applicable), steering head bearings, chain tensioner.
Preventative Maintenance:
Detailed schedules for oil changes, filter replacements, chain lubrication, spark plug checks, brake inspections, and valve clearance adjustments.
Troubleshooting:
Diagnostic flowcharts and common problem identification for engine performance, electrical issues, and starting problems.
Repair And Rebuild:
Step-by-step instructions for component repair and full system overhauls.
Component Replacement:
Guidance on replacing wear items and major components.
Torque Specifications:
Crucial torque values for all critical fasteners and bolts.
Electrical Troubleshooting:
Detailed diagnostic procedures and fault code interpretation (if applicable), circuit diagrams, component testing.
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine and transmission rebuilds, including electrical system diagnostics.
Engine Rebuild Level:
Full engine rebuild, including cylinder head, piston, crankshaft, and bearing service.
Suspension Service Level:
Complete fork and shock absorber overhaul, including seal replacement and valving inspection.
Engine Type:
4-stroke, DOHC, 4-valve, Single Cylinder
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 x 61.2 mm (2.8 x 2.4 in.)
Horsepower:
Approx. 22-24 HP (Varies by region and specific tuning)
Torque:
Approx. 18-19 Nm (13.3-14.0 lb-ft) @ 7,000 rpm
Engine Cooling:
Liquid-cooled
Fuel Delivery:
Keihin CVK34 carburetor (Note: Some later KLX250 models received fuel injection, but the 2012 typically features the CVK34 carburetor unless specifically a California emissions model which might have FI).
Recommended Fuel:
Unleaded gasoline, 87 octane minimum
Carburetor Model:
Keihin CVK34
Oil Capacity W Filter:
1.5 L (1.6 US qt)
Recommended Oil Grade:
SAE 10W-40 API SG or higher, JASO MA certified
Engine Oil Change:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Replacement:
Every 12,000 km (7,400 miles) or 12 months (with oil change)
Air Filter Cleaning:
Every 6,000 km (3,700 miles)
Spark Plug Check:
Every 6,000 km (3,700 miles)
Valve Clearance Check:
Every 24,000 km (14,900 miles)
Coolant Type:
Kawasaki Coolant or equivalent (ethylene glycol-based, 50/50 mix with distilled water)
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings. Carburetor jetting can sometimes be sensitive to altitude and modifications.
Engine Longevity:
The KLX250 engine is generally considered very reliable and durable when properly maintained. Issues are typically related to lack of maintenance or abuse rather than inherent design flaws.
