Category:
Dual-sport/Off-road motorcycle
Target Audience:
Enthusiasts and owners seeking to perform maintenance, repairs, and modifications on their Kawasaki KLX250R.
Segment Competitors:
Competed against models like the Honda XR250L, Suzuki DR250SE, and Yamaha WR250R in its era.
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder engine known for its reliability and manageable power delivery.
Suspension Type:
Long-travel, adjustable suspension providing excellent capability for both on-road and off-road riding.
Manual Value Proposition:
Provides comprehensive technical data, diagnostic procedures, and repair instructions essential for maintaining and restoring the KLX250R.
Systems Covered:
Engine, Fuel System, Carburetion, Ignition System, Cooling System, Lubrication System, Clutch, Transmission, Gearshift Mechanism, Drive Chain, Frame, Suspension (Front & Rear), Wheels, Tires, Brakes (Front & Rear), Steering, Electrical System, Lighting, Instruments, Troubleshooting, Maintenance, General Repair, Bodywork.
Page Count:
Estimated 300-400 pages (typical for this era and scope of coverage)
Manual Type:
Service Repair Manual
Format:
Likely available as a digital PDF download. Original manuals were printed.
Engine Mechanical:
Detailed procedures for disassembly, inspection, and reassembly of the engine, including piston, rings, cylinder, cylinder head, valves, camshaft, crankshaft, connecting rods, and bearings.
Fuel System Carburetion:
Comprehensive guide to the carburetor (likely Keihin CVK), including adjustment, cleaning, overhaul, jetting specifications, and troubleshooting fuel delivery issues.
Ignition System:
Information on the CDI ignition system, including timing specifications, troubleshooting ignition faults, and component testing (coil, pickup coil, CDI unit).
Cooling System:
Details on the liquid-cooled system, including radiator, hoses, water pump, coolant specifications, and bleeding procedures.
Lubrication System:
Information on oil pump, oil passages, oil filter, and oil change procedures, including oil type and capacity.
Transmission Drivetrain:
Step-by-step instructions for clutch operation, transmission disassembly/reassembly, gear inspection, shift drum and forks, and drive chain adjustment and maintenance.
Suspension And Steering:
Procedures for fork disassembly, seal replacement, oil level and viscosity, rear shock absorber inspection and adjustment, and steering head bearing maintenance.
Brakes Wheel Tires:
Guidance on brake pad replacement, caliper service, master cylinder overhaul, brake fluid specifications, bleeding, wheel bearing service, and tire pressure recommendations.
Electrical Lighting Instruments:
Wiring diagrams, troubleshooting for electrical faults, component testing (battery, stator, regulator/rectifier, lights, horn, starter), and instrument cluster maintenance.
Routine Maintenance:
Detailed schedules and procedures for oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain lubrication and adjustment, and general bolt torque checks.
Engine Overhaul:
Complete rebuild procedures for the engine, covering every internal component from top to bottom.
Carburetor Tuning Rebuild:
Instructions for fine-tuning carburetor settings for optimal performance and complete carburetor rebuilds.
Suspension Servicing:
Detailed steps for servicing front forks and rear shock absorber, including oil changes and seal replacements.
Brake System Service:
Procedures for brake pad replacement, caliper maintenance, and brake fluid bleeding.
Electrical Troubleshooting:
Systematic approach to diagnosing and repairing electrical issues using wiring diagrams and component testing.
Troubleshooting Guides:
Extensive troubleshooting sections covering common problems and their solutions for all major vehicle systems.
Depth:
Comprehensive coverage suitable for professional mechanics and experienced DIY enthusiasts, including detailed specifications, diagrams, and step-by-step repair instructions.
Engine Type:
Liquid-cooled, four-stroke, SOHC, 4-valve
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Horsepower:
Approx. 30-32 HP (at crank, depending on market and tuning)
Torque:
Approx. 18-20 lb-ft (at crank)
Fuel Type:
Unleaded gasoline (90+ octane recommended)
Ignition:
Digital CDI with electronic advance
Oil Capacity:
1.8 L (when filter is changed)
Recommended Oil:
SAE 10W-40 API SG or higher (check manual for specific viscosity recommendations based on temperature)
Oil Change:
Every 2,000 km (1,200 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed based on conditions. Replacement at 6,000 km (3,600 miles).
Spark Plug Service:
Inspect every 2,000 km (1,200 miles), replace at 6,000 km (3,600 miles) or if fouled.
Chain Maintenance:
Lubricate and adjust chain every 500 km (300 miles) or more frequently if riding in adverse conditions.
Valve Clearance Check:
Check every 6,000 km (3,600 miles)
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid (check manual for exact specification)
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol-based), 50/50 mix with distilled water.
Carburetor Cleaning:
Carburetors can sometimes get gummed up with age or if the bike sits for extended periods, requiring thorough cleaning and sometimes rebuild kits.
Suspension Seals:
Fork seals can wear over time, leading to oil leaks. Regular inspection and replacement are recommended.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent issues. Cleaning and dielectric grease application can prevent this.
Cam Chain Tensioner:
While generally robust, the cam chain tensioner mechanism can sometimes require attention or replacement due to wear.
