Segment:
Dual-sport motorcycle
Target Audience:
Off-road enthusiasts, commuters, adventure riders
Competitors 1995:
Honda XR250L, Yamaha WR250, Suzuki DR250SE
Primary Attributes:
Lightweight, agile, reliable off-road performance, street-legal capability
Manual Value:
Essential for maintaining peak performance and longevity of the KLX250-E3
Benefit To Owner:
Empowers owners to perform complex repairs and preventative maintenance, reducing reliance on external service centers.
Engine:
Engine assembly, disassembly, top-end, bottom-end, lubrication, cooling system, carburetion, ignition system, exhaust system
Transmission:
Gearbox disassembly and assembly, clutch operation, shift mechanism
Chassis:
Frame, suspension (front forks, rear shock absorber), steering, wheels, hubs, spokes, brakes (front and rear), drive chain
Electrical:
Wiring diagrams, lighting system, ignition system, charging system (stator, regulator/rectifier), battery, switches, instrumentation
Fuel System:
Fuel tank, fuel lines, carburetor (Kawasaki Keihin CVK34), fuel filter
Bodywork:
Seat, fuel tank cover, side covers, fenders, handlebars, controls
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, brake adjustments, spark plug replacement, valve clearance adjustment
Troubleshooting:
Diagnostic charts for common problems, electrical system fault finding
Repair:
Detailed step-by-step instructions for component removal, repair, and reinstallation
Disassembly Reassembly:
Complete breakdown and rebuild procedures for major components
Depth:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts
Torque Specifications:
Detailed torque values for critical fasteners
Clearances:
Specifications for valve clearances, bearing clearances, etc.
Diagrams Illustrations:
Exploded views, wiring diagrams, and detailed illustrations
Digital Format Notes:
Original printed manual, may be digitized by sellers (check specific listing)
Original Print Quality:
High quality, professional printing with clear diagrams
Original Binding:
Typically saddle-stitched or perfect bound
Original Paper Type:
Durable, semi-gloss paper stock suitable for workshop environments
Engine Type:
Four-stroke, DOHC, 4-valve, liquid-cooled single cylinder
Displacement:
249 cc (249 cubic centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm
Compression Ratio:
11.0:1
Horsepower Estimated:
Approximately 30-32 HP (at crank)
Torque Estimated:
Approximately 17-19 lb-ft (at crank)
Carburetor Model:
Kawasaki Keihin CVK34
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Oil Type Specification:
API SG, SAE 10W-40 motorcycle oil
Oil Capacity W Filter Change:
1.8 L (1.9 US qt)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water)
Ignition Type:
Digital CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR8E or equivalent
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-disc, cable-operated
Gear Ratios:
Detailed in manual (typically: 1st: 2.667, 2nd: 1.944, 3rd: 1.500, 4th: 1.250, 5th: 1.042, 6th: 0.879)
Final Drive:
O-ring sealed chain drive
Transmission Oil Type:
API GL-4 SAE 80 hypoid gear oil (manual specifies specific Kawasaki gear oil)
Transmission Oil Capacity:
Approximately 1.1 L (1.1 US qt)
Safety Certification:
Street-legal (DOT, EPA emissions compliant where applicable)
Braking System:
Front: Hydraulic disc; Rear: Drum brake (some variants may have disc)
Lighting:
Headlight, taillight, brake light, turn signals
Frame Construction:
High-tensile steel semi-double cradle frame
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators
Assistance Systems:
N/A (Basic motorcycle electronics)
Connectivity Features:
N/A (Mechanical and basic electrical systems)
Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions
Valve Clearance Check:
Every 6,000 km (3,600 miles)
Chain Lubrication Adjustment:
Every 500 km (300 miles)
Brake Fluid Change:
Every 2 years
Engine Oil Specification:
API SG, JASO MA, SAE 10W-40
Fork Oil Type:
SAE 10W (Kawasaki KHL15-10W recommended)
Coolant Specification:
50% Distilled Water / 50% Ethylene Glycol Antifreeze
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, brake pads, carburetor diaphragm
Carburetor Tuning:
Can be sensitive to altitude and temperature, requiring periodic adjustment.
Electrical Connections:
Corrosion on electrical connectors can cause intermittent issues, especially in damp environments.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and reliability in various segments, including off-road.
Klx Lineage:
The KLX line has a strong heritage in off-road racing and trail riding, evolving from earlier KDX and KX models.
Klx250 Development:
The KLX250 model was developed as a versatile dual-sport motorcycle offering both off-road prowess and street legality.
Production Era:
The KLX250-E3 model was produced for the 1995 model year, part of a generation that ran from the early to late 1990s.
