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1993-1997 Kawasaki KLX250R KLX250 KLX300R Service Repair Manual

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This service repair manual covers the KLX250R, KLX250, and KLX300R models from the first generation, produced between 1993 and 1997. These dual-sport and enduro motorcycles are known for their off-road...
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Art.-Nr: 140405
1993-1997 Kawasaki KLX250R KLX250 KLX300R Service Repair Manual
This service repair manual covers the KLX250R, KLX250, and KLX300R models from the first generation, produced between 1993 and 1997. These dual-sport and enduro motorcycles are known for their off-road capability and versatility, building on a strong heritage in off-road racing. With a 4-stroke, liquid-cooled, DOHC, single-cylinder engine, available in 249cc and 292cc displacements, these bikes offered a balanced performance suitable for both trail riding and everyday use. This comprehensive English-language manual provides factory-level detail essential for owners, mechanics, and technicians. It covers all major systems including the fuel, cooling, engine (top end, lubrication, right/left side assemblies, removal/installation), crankshaft, transmission, wheels, tires, final drive, brakes, suspension, steering, frame, and electrical system, complete with wiring diagrams. Procedures for maintenance, assembly, disassembly, troubleshooting, repair, component overhaul, and specification adjustments are thoroughly explained, ensuring the longevity and optimal performance of your KLX.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250R/KLX250/KLX300R
Model Codes:
KLX250-D1, KLX250-D2, KLX250-D3, KLX250-D4, KLX250-E1, KLX250-E2, KLX250-E3, KLX250G-1, KLX300-A2
Generation:
First Generation (1993-1997)
👋 Introduction
Market Position
Market Segment:
Dual-Sport / Enduro Motorcycle
Competitive Analysis
Competitors:
Yamaha WR250Z, Honda CR250R (off-road variants), Suzuki DR-Z series
Key Features
Target Audience:
Owners, mechanics, and enthusiasts of the Kawasaki KLX250R, KLX250, and KLX300R models from 1993-1997.
Value Proposition:
Provides essential factory-level diagnostic and repair information to maintain and restore these off-road capable motorcycles.
📋 Manual Details
Coverage
Coverage Areas:
General Information, Fuel System, Cooling System, Engine Top End, Engine Right Side/Left Side, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix, 1994 Model Supplement, KLX300R Supplement
Format
Manual Type:
Service Repair Manual
Language:
English
File Format:
PDF
📖 Manual Coverage
Systems
Systems Covered:
Engine (Top End, Lubrication, Right/Left Side Assemblies, Removal/Installation), Fuel System, Cooling System, Transmission, Crankshaft, Wheels, Tires, Final Drive, Braking System, Suspension (Front and Rear), Steering System, Frame, Electrical System (Wiring Diagrams Included)
Procedures
Procedures Included:
Maintenance, Assembly, Disassembly, Troubleshooting, Repair, Component Overhaul, Wiring Diagram Interpretation, Spec Adjustments
Depth
Technical Depth:
Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics. Covers detailed procedures for complete engine rebuilds, suspension tuning, and electrical system diagnostics.
📊 Manual Specifications
File Quality
Print Quality:
High Quality PDF
Printable:
All pages are printable
Delivery
Delivery Method:
Instant Download
Shipping Cost:
None
Compatibility
Operating Systems:
All Versions of Windows & Mac
Requirements
Software Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-cooled, DOHC, Single Cylinder
Performance
Displacement Klx250:
249 cc
Displacement Klx300:
292 cc
Bore X Stroke Klx250:
72.0 x 61.2 mm
Bore X Stroke Klx300:
78.0 x 61.2 mm
Compression Ratio Klx250:
10.0:1 (approx.)
Compression Ratio Klx300:
10.0:1 (approx.)
Fuel System
Fuel Delivery:
Carburetor (likely Keihin CV type)
Carburetor Size Klx250:
Likely 32-34mm
Carburetor Size Klx300:
Likely 34-35mm
Lubrication System
Oil Type:
API SG, SAE 10W-40 or 20W-50 Motorcycle Specific
Oil Capacity With Filter:
Refer to manual for exact capacity (typically around 1.8-2.0L)
🔧 Transmission
Gearbox
Transmission Type:
6-speed constant mesh
Gear Ratios
Gear Ratios:
Specific ratios available in manual
Clutch
Clutch Type:
Wet, multi-disc
Clutch Fluid:
Refer to manual for specification (typically dedicated clutch fluid or brake fluid DOT 3/4 for hydraulic systems)
📐 Dimensions
Weights
Dry Weight Klx250:
Approximately 118-125 kg (260-275 lbs) depending on trim/year
Dry Weight Klx300:
Approximately 125-130 kg (275-286 lbs)
Fuel Capacity:
Approximately 9.0 - 10.0 Liters (2.4 - 2.6 US gal)
🛡️ Safety Features
Features
Braking System:
Front: Disc, Rear: Disc
Brake Fluid:
DOT 3 or DOT 4
Tire Sizes:
Front: 3.00-21, Rear: 100/90-18 (typical, refer to manual for exact fitment)
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation)
Driver Assistance
ABS:
Not equipped
Ignition
Ignition System:
CDI (Capacitor Discharge Ignition)
Lighting
Headlight Type:
Halogen
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 2,000-3,000 km (1,200-1,800 miles) or 6 months
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions
Spark Plug Replacement:
Refer to manual, typically every 5,000-10,000 km (3,000-6,000 miles)
Fluid Specifications
Coolant Type:
Permanent type antifreeze (ethylene glycol based), 50/50 mix with distilled water
Fork Oil Type:
Refer to manual for viscosity (e.g., Showa SS-8 or equivalent 5W/10W)
Known Issues
Common Wear Items:
Clutch plates, valve guides, carburetor diaphragms, exhaust seals, wheel bearings.
Cooling System Considerations:
Regular coolant flushes and inspection of hoses and radiator fins are crucial for preventing overheating, especially under heavy use.
📚 Vehicle History
Brand Heritage
Kawasaki Offroad Legacy:
Kawasaki has a long-standing reputation in off-road and dual-sport motorcycles, with the KLX line evolving from earlier KX racing platforms.
Model Evolution
Klx Line Introduction:
The KLX250R and KLX300R were developed as versatile off-road and dual-sport machines, offering a balance of performance and usability.
Production
Production Period Covered:
1993, 1994, 1995, 1996, 1997
🏆 Awards & Recognition
Recognitions
Offroad Magazine Reviews:
While specific awards are rare for service manuals themselves, the KLX series received positive reviews for its capability and reliability in off-road and dual-sport applications during its production years.
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