Market Segment:
Dual-sport motorcycle, targeting riders seeking versatility for both on-road and off-road use.
Target Audience:
Enthusiasts and owners looking for comprehensive maintenance and repair information for their Kawasaki KLX250 model.
Competitors 1995:
Honda XR250L, Yamaha WR250, Suzuki DR250SE.
Vehicle Type:
Dual-sport motorcycle.
Engine Configuration:
Single-cylinder, four-stroke.
Suspension Setup:
Long-travel suspension for off-road capability.
Engine System:
Complete engine overhaul, including disassembly, inspection, assembly, tuning, and troubleshooting of all internal components.
Fuel System:
Carburetor (type and model specific) disassembly, cleaning, adjustment, rebuilding, and troubleshooting; fuel tank and fuel line maintenance.
Ignition System:
CDI ignition system, spark plug diagnosis and replacement, ignition coil testing, troubleshooting electrical faults related to ignition.
Transmission System:
Gearbox disassembly, inspection, repair, clutch operation, linkage adjustment, troubleshooting shifting issues.
Suspension System:
Front fork disassembly, seal replacement, oil level and type specifications, rear shock absorber inspection and adjustment.
Brake System:
Front and rear brake system maintenance, hydraulic fluid replacement, caliper inspection and servicing, brake pad replacement, bleeding procedure.
Cooling System:
Air-cooled engine specific maintenance, airflow management, potential for oil cooling system details if applicable.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system (stator and regulator/rectifier), starter motor, fuses, and troubleshooting electrical faults.
Frame And Bodywork:
Chassis inspection, bolt torque specifications, body panel removal and installation, seat, fenders, and handle bar maintenance.
Wheels And Tires:
Wheel bearing maintenance, spoke tension adjustment, tire pressure recommendations, rim maintenance.
Scheduled Maintenance:
Detailed maintenance schedule for routine checks, lubrication, filter replacements, and adjustments at specified intervals.
Troubleshooting Guides:
Systematic diagnostic procedures for common issues, symptom-based troubleshooting, and diagnostic flowcharts.
Repair Procedures:
Step-by-step instructions for component removal, replacement, and reassembly for all major systems.
Overhaul Procedures:
Comprehensive instructions for complete engine, transmission, and suspension component overhauls.
Adjustment Procedures:
Carburetor idle speed and mixture, clutch play, throttle cable free play, chain tension, suspension preload.
Diagnostic Capability:
Advanced diagnostic information for electrical and mechanical systems, including component testing and specifications.
Rebuild Capability:
Full engine and transmission rebuild instructions, including clearances, torque values, and critical assembly steps.
Specification Detail:
Precise technical specifications for all components, including measurements, tolerances, and performance data.
Engine Type:
4-stroke, SOHC, 2-valve per cylinder.
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm
Compression Ratio:
9.0:1 (typical for this era, confirm with manual)
Horsepower:
Approx. 21-24 HP @ 7,500 RPM (estimated, actual may vary slightly by region/tune)
Torque:
Approx. 15-17 lb-ft @ 6,000 RPM (estimated)
Carburetor Type:
Mikuni VM28SS (likely, confirm with manual for specific E3 variant)
Fuel Delivery:
Carburetor
Fuel Type:
Unleaded gasoline
Cooling Method:
Air-cooled
Oil Change Interval:
Every 3,000-5,000 km (or as per manual: typically 6 months or annually).
Air Filter Cleaning:
Every 1,000-2,000 km, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 6,000-10,000 km (specific plug type and gap critical).
Chain Lubrication Adjustment:
Every 500-1,000 km, or as needed based on slack.
Valve Clearance Check:
Typically at 10,000-15,000 km intervals (crucial for engine health).
Engine Oil Type:
API SG or higher, SAE 10W-40 or 20W-50 (verify with manual for ambient temperature suitability).
Engine Oil Capacity:
Approx. 1.7 Liters (1.8 US qt) without filter change; Approx. 1.8 Liters (1.9 US qt) with filter change (verify with manual).
Brake Fluid Type:
DOT 3 or DOT 4 (verify with manual, typically DOT 4 for disc brakes).
Fork Oil Type Level:
Specific fork oil weight (e.g., SAE 10W) and level/volume required (critical for suspension performance).
Carburetor Cleaning:
Carburetors can be prone to clogging from stale fuel or debris, requiring regular cleaning and proper fuel stabilizer use.
Valve Adjustment:
Valve clearance tightening over time is common, necessitating periodic checks and adjustments to maintain performance and prevent damage.
Rear Shock Wear:
Original rear shocks may lose damping effectiveness over time and miles, impacting ride quality and handling.
Chain And Sprockets:
Wear on the drive chain and sprockets is a standard maintenance item; proper lubrication and adjustment are key to longevity.
Clutch Cable Adjustment:
Routine adjustment of clutch cable free play is necessary for proper clutch engagement/disengagement.
Fork Seal Replacement:
Front fork seal leaks are a common repair for this type of motorcycle due to off-road use.
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for performance and innovation across various categories.
Klx Lineage:
The KLX line has been a staple for Kawasaki in the dual-sport and off-road segments, with the 250cc engine being a popular displacement for versatility.
Klx250 Production Years:
The KLX250 has seen production across several generations, with the early models dating back to the late 1970s/early 1980s. The E-series was a prominent generation.
Manufacturing Location:
Typically manufactured in Japan.
