Segment:
Dual-sport/Enduro motorcycle
Target Audience:
Owners, mechanics, and enthusiasts performing maintenance and repairs on the 1993 Kawasaki KLX250.
Contemporary Competitors:
Honda XR250L, Yamaha XT250, Suzuki DR250S.
Vehicle Focus:
Versatile off-road capability with on-road usability, known for its robust engine and reliable performance.
Engine:
Complete engine disassembly, assembly, inspection, tuning, and repair of all components including carburetor, ignition system, exhaust system, and cooling system.
Transmission:
Disassembly, inspection, repair, and reassembly of the gearbox, clutch, and shifting mechanisms.
Drivetrain:
Chain and sprocket inspection, adjustment, and replacement procedures.
Suspension:
Front fork (telescopic) disassembly, service, and adjustment. Rear shock absorber inspection and replacement. Swingarm and linkage maintenance.
Brakes:
Front and rear brake system service, including caliper overhaul, master cylinder service, pad replacement, hydraulic line inspection, and bleeding procedures.
Electrical System:
Wiring diagrams, component testing, troubleshooting for ignition, lighting, charging system (stator, regulator/rectifier), and starter motor.
Fuel System:
Carburetor disassembly, cleaning, adjustment, and overhaul. Fuel tank and petcock service.
Cooling System:
Radiator inspection, coolant replacement, and thermostat service (if applicable to this model).
Frame And Bodywork:
Inspection and repair of the frame, subframe, body panels, seat, and handlebars.
Wheels And Tires:
Wheel bearing inspection and replacement, tire mounting and balancing advice.
Maintenance:
Regular maintenance procedures, lubrication points, filter changes, spark plug replacement, and general tune-up instructions.
Troubleshooting:
Diagnostic guides and common problem identification for various systems.
Repair:
Step-by-step instructions for component overhaul and replacement.
Diagnostics:
Fault finding charts and diagnostic procedures for electrical and mechanical issues.
Specifications:
Detailed technical specifications, torque values, clearances, and adjustments for all components.
Depth Level:
Comprehensive - covers routine maintenance to full engine rebuilds and major component overhauls.
Digital Format Details:
Typically a PDF file, allowing for easy searching, zooming, and printing. May be image-based scans or OCR-processed text.
Print Quality:
Variable based on original source. High-quality reproductions ensure readability of diagrams and text.
Binding Type:
N/A (for digital format). If printed, typically spiral-bound or saddle-stitched for durability in a workshop environment.
Paper Type:
N/A (for digital format). Historically, workshop manuals used durable, often gloss-coated paper to withstand workshop conditions.
Engine Type:
Four-stroke, single-cylinder, DOHC, liquid-cooled
Displacement:
249 cc (15.2 cu in)
Bore X Stroke:
72.0 mm x 61.2 mm (2.83 in x 2.41 in)
Compression Ratio:
11.0:1
Horsepower:
Approximately 25-30 HP (estimate based on similar models of the era)
Torque:
Not readily available, but expected to be around 18-20 lb-ft.
Carburetor:
Keihin CVK34 (Constant Velocity)
Fuel Capacity:
2.6 US gal (9.8 L)
Ignition System:
Digital CDI
Lubrication System:
Wet sump
Cooling Method:
Liquid-cooled
Length:
Approximately 2210 mm (87.0 in)
Width:
Approximately 855 mm (33.7 in)
Height:
Approximately 1255 mm (49.4 in)
Wheelbase:
Approximately 1430 mm (56.3 in)
Dry Weight:
Approximately 123 kg (271 lbs)
Wet Weight:
Not specified, but typically around 130-135 kg with fluids.
Ground Clearance:
Approximately 315 mm (12.4 in)
Seat Height:
Approximately 895 mm (35.2 in)
Safety Certification:
Meets DOT and EPA regulations for on-road use in many markets, as applicable.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Headlight, taillight, turn signals, brake lights.
Frame Construction:
Steel semi-double cradle frame.
Infotainment Features:
N/A - This is a 1993 motorcycle, infotainment systems were not a feature.
Driver Assistance Features:
N/A - This is a 1993 motorcycle, electronic rider aids were not a feature.
Connectivity Features:
N/A - This is a 1993 motorcycle, connectivity features were not a feature.
Oil Change Interval:
Typically every 3,000-5,000 km (2,000-3,000 miles) or annually, as per manual recommendations.
Air Filter Cleaning:
Check and clean every 1,000-2,000 km (600-1,200 miles), replace as needed.
Spark Plug Replacement:
Typically every 6,000-10,000 km (4,000-6,000 miles).
Valve Clearance Check:
Every 8,000-12,000 km (5,000-7,500 miles).
Engine Oil Type:
API SG, SF or higher, SAE 10W-40 motorcycle oil recommended. Specific grade may vary, check manual for exact specification.
Engine Oil Capacity:
Approx. 1.7 L (1.8 US qt) without filter change, 1.9 L (2.0 US qt) with filter change.
Coolant Type:
Permanent type antifreeze coolant mixed with distilled water in a 50:50 ratio. Refer to manual for specific coolant formulation.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Carburetor Issues:
Potential for gumming if fuel sits for extended periods, requiring thorough cleaning and adjustment.
Suspension Wear:
Fork seals can wear over time, leading to oil leaks. Rear shock absorber may lose damping ability with age and mileage.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues, especially in harsh environments.
Kawasaki Legacy:
Kawasaki has a long history of producing performance-oriented motorcycles across various categories, including dirt bikes and dual-sports.
Klx Lineage:
The KLX series has been a mainstay for Kawasaki in the dual-sport segment, evolving from earlier models to incorporate modern technology and performance improvements.
Klx250 Development:
The KLX250 was designed to offer a balance of off-road prowess and street legality, making it a versatile choice for adventure riding and commuting.
Production Period:
The KLX250 model has had a long production run, with variations and updates over the years.
