🏷️ Basic Information

Make:

Kawasaki

Model:

KLX250

Model Variant:

KLX250R

Year:

1996

Chassis Code:

KLX250-D1

Engine Code:

KL250GE

👋 Introduction

Market Segment:

Dual-sport / Off-road motorcycle.

Competitors 1996:

Honda CRF250L (later model), Yamaha WR250R, Suzuki DR-Z250, KTM EXC series (competition-focused).

Klx250R Focus:

The KLX250R was a more off-road oriented version of the KLX250, featuring longer travel suspension, higher ground clearance, and often a more aggressive engine tune compared to the standard KLX250S or dual-sport variants.

1996 Model Significance:

Represents a period of development in Japanese dual-sport motorcycles, balancing off-road capability with street-legality.

📋 Manual Details

Manual Type:

Repair Service Manual

Language:

English

Format:

Digital (likely PDF, requires confirmation)

Page Count:

Approximately 300-400 pages (typical for this era and type of manual)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components including cylinder, piston, crankshaft, connecting rod, valves, camshaft, timing system.

Fuel System:

Carburetor (Mikuni VM24SS likely) tuning, cleaning, repair, jetting specifications, fuel pump, fuel lines, and tank maintenance.

Ignition System:

CDI ignition system, spark plug specifications, ignition timing, coil testing, troubleshooting.

Transmission Drivetrain:

Clutch operation, adjustment, and repair; gearbox disassembly, inspection, and repair; chain drive maintenance, lubrication, and adjustment.

Cooling System:

Liquid-cooled system, radiator maintenance, coolant specifications and capacity, fan operation, thermostat testing.

Suspension Frontend:

Front fork disassembly, seal replacement, oil type and level, spring specifications, damper adjustments, steering head bearing service.

Suspension Rear:

Monoshock rear suspension system, linkage maintenance, shock absorber service, adjustment of pre-load and damping.

Braking System:

Front and rear disc brake systems, caliper disassembly, pad replacement, fluid type (DOT 4 likely), bleeding procedures, master cylinder service.

Electrical System:

Wiring diagrams, battery specifications, charging system (stator, regulator/rectifier), lighting system, horn, starter motor, fuses, and troubleshooting.

Chassis Frame:

Frame inspection, swingarm service, wheel bearings, spoke tensioning, general chassis integrity checks.

Bodywork Trim:

Fairings, seat, fenders, and other body panels removal, installation, and maintenance.

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug inspection, air filter cleaning/replacement, brake pad checks.

Troubleshooting:

Diagnostic procedures for common running issues, electrical faults, and mechanical problems with step-by-step guidance.

Engine Rebuild:

Detailed instructions for engine overhaul, including torque specifications, tolerances, and component replacement.

Suspension Overhaul:

Complete guides for front fork and rear shock absorber service, including fluid changes and seal replacements.

Carburetor Tuning:

Step-by-step guide for carburetor adjustment, cleaning, and rebuilding, including jetting information.

Electrical Diagnostics:

Procedures for testing electrical components, diagnosing circuit faults using wiring diagrams, and identifying common failures.

Depth:

Comprehensive. Covers from basic routine maintenance to complete engine and chassis overhauls, including detailed specifications and troubleshooting.

📊 Manual Specifications

File Format:

Likely PDF (Digital Download). Searchable text and high-resolution scans are expected for optimal usability.

Print Quality:

High-resolution scans of original factory manual, ensuring clarity of diagrams and text.

Binding Type:

N/A (Digital format). If printed, typically comb or spiral bound for lay-flat use in a workshop.

Paper Type:

N/A (Digital format). Original manuals would use durable paper for workshop use.

⚙️ Engine Specifications

Engine Type:

Four-stroke, Liquid-cooled, DOHC, Single-cylinder

Displacement:

249 cc

Bore X Stroke:

72.0 mm x 61.2 mm

Compression Ratio:

11.0:1

Horsepower:

Approx. 30-32 HP (at the crankshaft, stock).

Torque:

Approx. 18-20 lb-ft (at the crankshaft, stock).

Carburetor:

Mikuni VM24SS (likely, specific variant may vary)

Fuel Capacity:

Approx. 2.5 gallons (10 Liters)

Oil Type:

API SE, SF or SG class SAE 10W-40 motorcycle oil recommended. Check manual for specific viscosity based on temperature.

Coolant Type:

Permanent-type antifreeze coolant (50% solution of ethylene glycol).

Coolant Capacity:

Approx. 1.5 Liters

🔧 Transmission

Transmission Type:

6-speed, constant mesh

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain

Transmission Oil Type:

API GL-4 SAE 80 hypoid gear oil recommended (refer to manual for specific type and capacity).

📐 Dimensions

Length:

Approx. 2,185 mm (86.0 in)

Width:

Approx. 840 mm (33.1 in)

Height:

Approx. 1,220 mm (48.0 in)

Wheelbase:

Approx. 1,430 mm (56.3 in)

Dry Weight:

Approx. 115 kg (253.5 lbs)

Wet Weight:

Approx. 124 kg (273.4 lbs) (with all fluids)

Front Suspension Travel:

Approx. 280 mm (11.0 in)

Rear Suspension Travel:

Approx. 270 mm (10.6 in)

Front Tire Size:

80/100-21 51P

Rear Tire Size:

100/100-18 59P

Wheelbase Type:

Spoked wheels

🛡️ Safety Features

Safety Features Motorcycle:

N/A (Motorcycles are not rated by organizations like NHTSA or IIHS). Focus is on rider skill and proper maintenance.

Brakes:

Hydraulic disc brakes front and rear for strong stopping power.

Lighting:

Headlight, taillight, brake lights, turn signals for visibility.

Frame Construction:

Strong steel frame designed for off-road abuse.

💡 Technology Features

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, and indicator lights. Basic but functional for its purpose.

ABS:

Not available on this model.

Connectivity Features:

None. This is a mechanically focused motorcycle.

🔧 Maintenance

Oil Change Interval:

Every 3,000 km (1,860 miles) or 6 months, whichever comes first. Check manual for specific conditions.

Air Filter Maintenance:

Clean every 1,000 km (620 miles), replace as needed based on operating conditions (dusty environments require more frequent cleaning).

Spark Plug Inspection:

Inspect every 3,000 km (1,860 miles), replace as needed. Recommended gap: 0.7-0.8 mm.

Chain Maintenance:

Lubricate every 500 km (310 miles) or after riding in wet conditions. Adjust tension every 1,000 km (620 miles).

Brake Fluid Type:

SAE J1703 or FMVSS No. 116 DOT 4

Fork Oil Type And Level:

Kawasaki KHL15-10 (or equivalent SAE 15W fork oil). Oil level: 130 mm from top of inner tube with spring removed and fork fully compressed. (Refer to manual for exact specification).

Carburetor Fouling:

Like many carbureted bikes of this era, susceptible to gumming if fuel sits for extended periods, requiring cleaning.

Fork Seal Leaks:

Can be prone to fork seal leaks, especially if subjected to harsh off-road use. Routine inspection and replacement are advised.

Electrical Connections:

Corrosion or loosening of electrical connectors can cause intermittent issues. Regular inspection and dielectric grease application is beneficial.

📚 Vehicle History

Kawasaki Motorsports:

Kawasaki has a long and storied history in motorsports, particularly in off-road and motocross racing, lending credibility to their dual-sport models.

Klx Lineage:

The KLX line has evolved significantly over the years, with the 250cc platform being a staple. The KLX250R was a more performance-oriented iteration for its time.

Klx250R Production Era:

The KLX250R was produced through the 1990s, with the platform seeing continuous updates leading to more modern iterations like the KLX250S and KLX300.

🏆 Awards & Recognition

Klx250R Reputation:

While specific awards for the 1996 KLX250R are uncommon, the KLX platform itself has a strong reputation for reliability and off-road capability within its class.