Vehicle Segment:
Dual-sport / Off-road motorcycle
Target Audience:
Enthusiasts, off-road riders, trail riders, daily commuters looking for a versatile and robust machine.
Key Competitors Era:
Honda XR250L, Yamaha XT250, Suzuki DR250S.
Versatility:
Designed for both on-road legality (with appropriate modifications/accessories for specific markets) and off-road capability, offering a good balance for diverse riding scenarios.
Durability:
Known for its robust construction and reliable engine, suitable for demanding off-road conditions.
Model Years Covered:
1993, 1994, 1995, 1996, 1997
Regional Variants Covered:
Likely covers models sold in North America, Europe, and other major markets, but specific regional variations should be cross-referenced with vehicle VIN.
Estimated Page Count:
400-600 pages (typical for comprehensive workshop manuals of this era)
Manual Classification:
Workshop Service Repair Manual
Format:
Digital (PDF) - Typically provided as a downloadable file for ease of access and searching.
Engine Mechanical:
Complete overhaul procedures, cylinder head, valve train, piston and connecting rod, crankshaft and transmission, lubrication system, cooling system, carburetor and fuel system (including fuel tank, fuel pump, and lines).
Engine Electrical:
Ignition system, starting system, charging system (alternator, regulator/rectifier), lighting system, battery maintenance, wiring diagrams, troubleshooting of electrical faults.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox overhaul, gear shift mechanism, final drive (chain and sprockets), lubrication and maintenance.
Suspension Steering:
Front fork (damping, seals, oil levels, spring replacement), rear shock absorber, swingarm and linkage, wheel bearings, steering head bearings, steering stem and handle-bars.
Braking System:
Front and rear brake caliper overhaul, master cylinder, brake lines, brake pads, brake fluid specifications, bleeding procedures, brake disc inspection.
Frame Bodywork:
Frame inspection and repair, fuel tank removal and installation, seat, fenders, side covers, exhaust system removal and installation, stand, footpegs.
Preventative Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement, brake inspection, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common problems, fault finding charts, electrical diagnostic techniques, engine performance issues, starting difficulties.
Repair And Rebuild:
Step-by-step disassembly and reassembly instructions for all major components, torque specifications for critical fasteners, clearance measurements and adjustments, sealing procedures.
Component Specific Procedures:
Carburetor tuning and rebuilding, front fork oil change and seal replacement, rear shock servicing, wheel truing, valve clearance adjustment.
Diagnostic Capability:
Advanced diagnostic procedures for electrical and mechanical systems, including testing of sensors, ignition components, and fuel delivery systems.
Rebuild Instructions:
Comprehensive instructions for full engine rebuilds, transmission overhauls, and suspension component overhauls, including detailed specifications and tolerances.
Special Tools:
Identification and usage of specialized tools required for specific maintenance and repair procedures (e.g., flywheel holder, clutch spring compressor).
Engine Type:
Four-stroke, DOHC, single-cylinder, liquid-cooled
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm (Approximate, common specification for this generation)
Compression Ratio:
11.0:1 (Typical for this model)
Horsepower:
Approx. 20-25 HP (Depending on market and specific tuning, manufacturer ratings varied)
Torque:
Approx. 15-18 lb-ft (Depending on market and specific tuning)
Fuel Delivery:
Carbureted (Typically Mikuni VM series or similar) - Specific model may have different carburetor variants (e.g., TM series). Manual will detail specific carburetor model and jetting.
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 2.6 US gallons (9.8 Liters)
Lubrication System:
Wet sump
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
Approx. 1.7 Liters (with filter change)
Crash Test Ratings:
N/A (Motorcycles are not typically rated by consumer safety organizations like NHTSA or Euro NCAP).
Braking System Type:
Front: Disc brake. Rear: Disc brake. (ABS was not available on this model).
Lighting:
Halogen headlight, LED tail light and indicators (depending on market configuration).
Frame Construction:
High-tensile steel perimeter frame designed for off-road durability and stability.
Suspension Compliance:
Long-travel suspension provides absorption over rough terrain, contributing to rider control and comfort.
Engine Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first. (Check manual for specific interval).
Air Filter Cleaning Interval:
Every 1,000 km (600 miles) or 6 months, especially if used in dusty conditions. Replace every 2 years or as needed.
Spark Plug Replacement Interval:
Every 6,000 km (3,600 miles) or 12 months. Inspect and clean more frequently.
Chain Lubrication And Adjustment Interval:
Every 500 km (300 miles) or after washing/wet riding. Adjust slack to 20-30mm.
Front Fork Oil Type:
Kawasaki KHL15-10 (or equivalent SAE 15W fork oil). Specific oil level and quantity detailed in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant Type:
Permanent type antifreeze coolant mixed with distilled water in a 50:50 ratio.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, steering head bearings, fork seals, carburetor jets (can clog if fuel is left sitting).
Carburetor Maintenance:
Regular cleaning and re-jetting may be necessary for optimal performance, especially if the bike sits for extended periods. The manual provides detailed instructions.
Engine Top End Life:
With proper maintenance, the top end (piston, rings, valves) can last for tens of thousands of miles. The manual outlines wear tolerances and rebuild procedures.
Kawasaki Motorcycle Legacy:
Kawasaki Heavy Industries has a long-standing reputation for producing high-performance and reliable motorcycles across various segments, including off-road and dual-sport.
Klx Series Development:
The KLX series is Kawasaki's dedicated line of off-road and dual-sport motorcycles, known for their versatility and capability in both dirt and street environments. The KLX250R represented an evolution of Kawasaki's 250cc off-road platform.
Manufacturing Location:
Typically manufactured in Japan.
Model Lifespan:
The KLX250 platform has been in continuous production for many years, with various iterations and upgrades. This specific manual covers the 1993-1997 models, which were part of the early generations of the liquid-cooled KLX250.
