Segment:
Dual-sport / Enduro motorcycle
Target Audience:
Enthusiasts, mechanics, owners seeking to maintain and repair their Kawasaki KLX 250 VB.
Competitors:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250
Vehicle Focus:
Versatile performance for both on-road and off-road riding, known for reliability and manageable power delivery.
Manual Value:
Essential resource for owners to perform maintenance, troubleshoot issues, and undertake repairs, potentially saving significant costs compared to professional servicing.
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul
Estimated Pages:
Over 500 pages (typical for comprehensive workshop manuals)
Type:
Workshop Service Manual
Format:
Digital (PDF) - Searchable and Printable
Engine Systems:
Top End (Cylinder Head, Valves, Camshaft), Bottom End (Crankshaft, Piston, Connecting Rod), Lubrication System, Cooling System, Fuel System (Carburetion/Injection), Ignition System, Starting System, Exhaust System
Drivetrain Systems:
Clutch, Transmission (Gearbox), Final Drive (Chain and Sprockets)
Chassis Systems:
Frame and Subframe, Suspension (Front Forks, Rear Shock Absorber), Steering, Wheels and Tires, Brakes (Front and Rear), Electrical System (Wiring Diagrams, Lighting, Battery, Ignition Components)
Bodywork And Trim:
Fairings, Seat, Handlebars, Footpegs, Body Panels
Routine Maintenance:
Oil Changes, Filter Replacements, Chain Adjustment and Lubrication, Spark Plug Checks, Air Filter Cleaning/Replacement, Brake Pad Inspection, Tire Pressure Checks, Valve Clearance Adjustment
Major Repairs:
Engine Rebuild (Top and Bottom End), Transmission Overhaul, Suspension Service and Rebuild, Brake System Bleeding and Component Replacement, Electrical Troubleshooting and Component Replacement
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting Guides, Fault Code Interpretation (if applicable)
Special Tools:
Identification of required special tools and their usage
Depth:
Comprehensive: Covers everything from routine maintenance to complete engine and transmission overhauls, including detailed torque specifications, clearances, and diagnostic procedures.
Searchability:
Fully searchable text for quick information retrieval.
Printability:
High-resolution pages suitable for printing specific sections or the entire manual.
Binding Recommendation:
If printed, recommend comb binding or a binder for easy page turning and use in a workshop environment.
Paper Recommendation:
For printed copies, recommend durable, coated paper to withstand workshop conditions.
Type:
Four-stroke, DOHC, 4-valve, Single Cylinder
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 x 61.2 mm (typical for this generation)
Compression Ratio:
11.0:1 (typical)
Horsepower:
Approximately 22-24 HP (at crankshaft, depending on market and tuning)
Torque:
Approximately 17-19 lb-ft (at crankshaft, depending on market and tuning)
Fuel Delivery:
Carburetor (Keihin CVK34 on many models, but some later or specific market versions may have EFI - manual will specify exact type).
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Type Recommendation:
API SG or SH, SAE 10W-40 or 20W-50 motorcycle oil (manual will provide specific Kawasaki recommendation).
Oil Capacity With Filter:
Approx. 1.7 L (1.8 US qt) (manual will confirm)
Cooling System:
Liquid-cooled
Ignition System:
Digital CDI with electronic advance
Type:
6-speed constant mesh
Gear Ratios:
Specific ratios will be detailed in the manual (e.g., 1st: 2.333, 2nd: 1.727, 3rd: 1.316, 4th: 1.091, 5th: 0.958, 6th: 0.840 - typical values)
Final Drive:
Sealed O-ring chain, 14T front sprocket, 42T rear sprocket (typical)
Transmission Oil Type:
API GL-4, SAE 80W-90 hypoid gear oil (manual will specify exact type and capacity)
Length:
Approx. 2,180 mm (85.8 in)
Width:
Approx. 800 mm (31.5 in)
Height:
Approx. 1,165 mm (45.9 in)
Wheelbase:
Approx. 1,430 mm (56.3 in)
Ground Clearance:
Approx. 255 mm (10.0 in)
Seat Height:
Approx. 865 mm (34.1 in)
Curb Weight:
Approx. 132 kg (291 lbs) (depending on equipment)
Fuel Tank Capacity:
Approx. 7.2 L (1.9 US gal)
Front Suspension:
43mm Inverted Telescopic Fork with Adjustable Preload (typical)
Rear Suspension:
Uni-Trak with Adjustable Preload and Rebound Damping
Front Tire Size:
80/100-21 M/C 51P (typical)
Rear Tire Size:
100/100-18 M/C 59P (typical)
Front Brake:
250mm Petal Disc (typical)
Rear Brake:
240mm Petal Disc (typical)
Wheel Bolt Pattern:
N/A (Motorcycle specific hub mounting)
Crash Test Results:
Not applicable for motorcycles in the same way as cars; focus is on design safety and rider protection features.
Braking System:
Dual petal disc brakes for enhanced stopping power and heat dissipation.
Lighting:
Headlight, taillight, brake lights, turn signals for visibility.
Frame Construction:
High-tensile steel perimeter frame designed for rigidity and impact resistance.
Ergonomics:
Designed for rider control and stability.
Instrument Cluster:
Digital speedometer, analog tachometer, odometer, trip meter, fuel gauge, clock, indicator lights.
ABS:
Anti-lock Braking System (ABS) was optional on some models/markets, or not available on the base VB model. Manual will specify if applicable.
Connectivity Features:
No integrated smartphone connectivity or advanced electronic rider aids typical of modern automobiles.
Oil Change:
Every 3,000 km (approx. 1,800 miles) or 6 months, whichever comes first (refer to manual for exact recommendation).
Air Filter Cleaning:
Every 6,000 km (approx. 3,700 miles) or as needed based on riding conditions.
Valve Clearance Check:
Every 12,000 km (approx. 7,500 miles) (critical for engine longevity).
Chain Maintenance:
Lubricate and adjust chain every 800 km (approx. 500 miles) or after riding in wet conditions.
Engine Oil Specification:
API SG or SH, JASO MA, SAE 10W-40 or 20W-50 Motorcycle Oil (e.g., Kawasaki Genuine R4 10W-40).
Coolant Type:
Permanent type (ethylene glycol based) antifreeze coolant with distilled water (50:50 mix).
Brake Fluid Type:
DOT 4 (refer to manual for specific caliper manufacturer recommendation if different).
Common Wear Items:
Clutch plates, brake pads, tires, chain and sprockets, fork seals due to typical dual-sport use.
Potential Engine Issues:
Valve clearance tightening over time is a common maintenance item. Overheating if coolant levels are not maintained. Carburetor gumming if left unused for extended periods without fuel stabilizer.
Electrical Concerns:
Corrosion in connectors or switches, particularly on bikes used extensively off-road. Battery maintenance.
Kawasaki Legacy:
Kawasaki Heavy Industries boasts a long history in motorcycle manufacturing, known for performance and innovation in various racing and street bike categories.
Klx Lineage:
The KLX series has a lineage of off-road and dual-sport motorcycles dating back decades, evolving with technological advancements in engines, suspension, and chassis design.
Klx250 Specifics:
The KLX250 has been a popular model, offering a balance of off-road capability and street legality, with updates over the years including fuel injection on some variants and revised styling.
Manufacturing Location:
Primarily manufactured in Japan, with potential assembly in other regions depending on market.
