Target Audience:
Enthusiast owners, independent repair shops, Kawasaki dealerships
Value Proposition:
Provides essential technical data for maintaining and repairing the 1993 Kawasaki KLX250 D1, saving costs on dealership services.
Comprehensiveness:
Covers all major mechanical and electrical systems of the specified model year.
Accuracy:
Based on original factory documentation for precise specifications.
Engine:
Complete disassembly, inspection, assembly, tuning, diagnostics
Fuel System:
Carburetor (Mikuni VM26SS), fuel pump, fuel tank, fuel lines
Ignition System:
CDI, spark plugs, ignition timing, coil
Lubrication System:
Oil pump, oil filter, oil passages, lubrication intervals
Cooling System:
Liquid-cooled (radiator, fan, coolant hoses, thermostat)
Transmission:
6-speed gearbox, clutch assembly, gear shift mechanism
Drivetrain:
Chain drive, sprockets, final drive maintenance
Suspension:
Front forks (USD), rear shock absorber, linkage system, adjustments
Brakes:
Front disc brake, rear drum brake, hydraulic system, caliper service
Wheels Tires:
Wheel bearing service, spoke tension, tire pressure recommendations
Electrical System:
Wiring diagrams, lighting, battery, charging system, fuses, switches
Chassis Frame:
Frame inspection, steering head bearing service
Bodywork:
Fairings, fenders, seat, fuel tank removal and installation
Maintenance:
Regular checks, lubrication, filter replacement, spark plug replacement
Troubleshooting:
Diagnostic charts for common problems (starting issues, engine noise, electrical faults)
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly
Adjustments:
Carburetor tuning, clutch adjustment, brake lever adjustment, suspension settings
Specifications:
Torque values, clearances, fluid capacities, engine timings
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and electrical system diagnostics)
Type:
Four-stroke, single-cylinder, DOHC, 4-valve
Bore X Stroke:
66.0 x 72.0 mm
Cooling System:
Liquid-cooled
Horsepower Estimated:
Approx. 28-30 HP (subject to tune and exact configuration)
Torque Estimated:
Approx. 20-22 Nm (subject to tune and exact configuration)
Carburetor Type:
Mikuni VM26SS
Fuel Capacity:
12 Liters (approx.)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Change:
Every 3,000 km or 6 months
Air Filter:
Clean every 3,000 km, replace every 6,000 km or as needed
Spark Plug:
Inspect every 6,000 km, replace every 12,000 km
Valve Clearance:
Inspect every 12,000 km
Engine Oil Capacity:
1.7 Liters (without filter), 1.8 Liters (with filter)
Coolant Type:
Permanent type anti-freeze (ethylene glycol based, 50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4
Carburetor Clogging:
Can be prone to carburetor jetting issues if not maintained with clean fuel.
Cam Chain Tensioner:
Early models might exhibit noise from the cam chain tensioner; manual details inspection and replacement.
Suspension Seals:
Like many bikes of this era, fork seals can degrade over time and require replacement.
Kawasaki Motorsports:
Kawasaki has a long-standing history in motorcycle racing and off-road performance.
Klx Lineage:
The KLX line is known for its dual-sport capabilities, bridging the gap between dirt bikes and street-legal motorcycles.
Klx250 1993 Context:
The 1993 model represents a refinement of the earlier KLX250 models, featuring improved suspension and engine tuning for the era.
Manufacturing Period:
1970s - present (with many iterations)
Original Market:
Primarily North America and Japan
