Vehicle Segment:
Dual-sport/Enduro motorcycle, known for its versatility on both off-road trails and paved roads.
Target Audience:
Enthusiasts seeking a reliable, relatively lightweight, and capable off-road capable motorcycle for recreational riding, trail exploration, and light commuting.
Competitors 1994:
Honda XR250L, Yamaha WR250, Suzuki DR250SE.
Klx250 Appeal:
Robust Kawasaki build quality, user-friendly power delivery, capable suspension for varied terrain, and a reputation for reliability in the dual-sport category.
Systems Covered:
Engine (Internal & External), Fuel System, Carburetion, Ignition System, Electrical System (Lighting, Charging, Starting), Transmission, Clutch, Drivetrain (Chain & Sprockets), Suspension (Front & Rear), Braking System (Front & Rear), Wheels & Tires, Frame, Bodywork, Chassis, Lubrication, Cooling System (Air-cooled), Troubleshooting, Specifications, Diagrams, Maintenance Schedules.
Total Pages:
Approximately 350-450 pages (estimated for a comprehensive workshop manual of this era).
Type:
Workshop Service Repair Manual
Format:
Digital (PDF) or Printed
Engine Mechanical:
Complete overhaul, disassembly, inspection, and reassembly of the engine components, including cylinder head, pistons, rings, crankshaft, connecting rods, valves, timing mechanism, and oil pump.
Fuel System Carburetion:
Detailed procedures for carburetor removal, cleaning, adjustment, rebuilding, fuel tank maintenance, fuel lines, and fuel filter replacement.
Ignition System:
Information on spark plugs, ignition timing, CDI unit, ignition coils, and troubleshooting ignition-related problems.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, battery), lighting (headlight, taillight, turn signals), and horn.
Transmission Drivetrain:
Service and repair procedures for the gearbox, clutch (operation, adjustment, replacement), drive chain, and sprockets, including lubrication and tension adjustment.
Suspension Steering:
Front fork servicing (oil changes, seal replacement, spring inspection), rear shock absorber maintenance, linkage lubrication, and steering head bearing service.
Braking System:
Front and rear brake caliper overhaul, brake pad replacement, brake fluid bleeding, brake line inspection and replacement, and master cylinder service.
Chassis Bodywork:
Frame inspection, swingarm pivot service, footrest replacement, seat removal, fuel tank mounting, and general body panel care.
Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake adjustments, coolant checks (if applicable to specific models, though KLX250 is air-cooled), and general bolt torque checks.
Troubleshooting:
Systematic diagnostic guides for common running problems, starting issues, electrical faults, and performance anomalies, often with symptom-based troubleshooting trees.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair or replacement, and reassembly for nearly all major vehicle systems.
Special Tools:
Identification and usage of specialized tools required for specific repair or maintenance procedures, often referencing Kawasaki part numbers for these tools.
Depth:
Comprehensive rebuilds, advanced diagnostics, detailed specifications for measurements and tolerances, torque specifications for every fastener, and clear exploded views for component identification.
Digital Format Details:
Searchable PDF with high-resolution scanned pages, allowing for easy navigation and printing of individual sections. Bookmarked for quick access to major sections.
Print Quality Description:
High-quality scans ensuring clear text and legible diagrams. For printed versions: durable paper stock, clear printing, and robust binding.
Binding Type:
For printed manuals: Typically spiral-bound or comb-bound for lay-flat usability in a workshop environment, or professionally bound.
Paper Type:
For printed manuals: Heavy-duty paper stock designed to withstand grease and shop use. For digital: High-resolution image files.
Engine Type:
Four-stroke, DOHC, single-cylinder, air-cooled.
Displacement:
249 cc (249cc)
Bore X Stroke:
72.0 x 61.2 mm (2.83 x 2.41 in)
Horsepower Estimated:
Approximately 20-24 hp (actual figures may vary slightly based on tuning and market).
Torque Estimated:
Approximately 16-19 lb-ft (actual figures may vary slightly).
Carburetor Type:
Mikuni VM26SS (or similar single carburetor setup).
Fuel Capacity:
Approximately 2.6 US gallons (9.8 liters).
Oil Type Specification:
SAE 10W-40 or SAE 20W-50 API SG or higher, JASO MA certified motorcycle oil.
Oil Capacity With Filter Change:
Approximately 1.5 - 1.7 Liters (1.6 - 1.8 US quarts).
Length:
Approximately 2180 mm (85.8 in)
Width:
Approximately 805 mm (31.7 in)
Height:
Approximately 1160 mm (45.7 in)
Wheelbase:
Approximately 1430 mm (56.3 in)
Dry Weight:
Approximately 120 kg (264.6 lbs)
Wet Weight Estimated:
Approximately 130-135 kg (286-298 lbs) with all fluids.
Front Suspension Travel:
Approximately 250 mm (9.8 in)
Rear Suspension Travel:
Approximately 230 mm (9.1 in)
Infotainment System:
N/A (This is a 1994 motorcycle, no electronic infotainment systems present).
Electronic Aids:
N/A (No electronic rider aids like ABS, traction control, or riding modes).
Connectivity Features:
N/A (No wireless connectivity or smart device integration).
Gauge Cluster:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights for neutral, high beam, and turn signals.
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first. Manual will specify exact intervals and checks.
Spark Plug Inspection:
Every 6,000 km (3,700 miles).
Air Filter Cleaning:
Every 3,000 km (1,800 miles) or more frequently in dusty conditions.
Drive Chain Maintenance:
Lubrication and tension check every 1,000 km (600 miles). Adjustment as needed.
Fork Oil Type Capacity:
Refer to manual for specific viscosity (e.g., Showa SS-10 or equivalent) and fill level (typically measured from the top of the fork tube with the spring removed).
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation).
Common Wear Items:
Clutch plates, brake pads, drive chain and sprockets, fork seals, and carburetor jets due to fuel variations or deposits.
Carburetor Idling:
Can sometimes develop issues with smooth idling if the carburetor is not kept clean and properly adjusted, particularly the pilot jet.
Kawasaki Motorcycles:
Kawasaki Heavy Industries' motorcycle division has a long history of producing high-performance and reliable motorcycles across various categories, including off-road, sport, cruiser, and touring.
Klx Series Development:
The KLX line has evolved significantly since its inception, with the KLX250 evolving from earlier dual-sport models. The 1994 model represents a refinement of this lineage, focusing on off-road capability with dual-sport practicality.
Klx250 Production Years:
The KLX250 platform has been in continuous production in various forms and markets for decades, with significant updates in design and technology occurring periodically.
