🏷️ Basic Information

Make:

Kawasaki

Model:

KLX 250

Type:

Dual-Sport Motorcycle

👋 Introduction

Segment:

Lightweight Dual-Sport Motorcycle

Target Audience:

Off-road enthusiasts, adventure riders, commuters seeking versatility.

Key Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250.

Model Attributes:

Durable construction, user-friendly ergonomics, capable off-road and on-road performance.

Manual Value Proposition:

Empowers owners to perform comprehensive maintenance and repairs, saving time and money, and ensuring optimal performance and longevity.

📋 Manual Details

Coverage Summary:

Comprehensive service, repair, and maintenance procedures for the Kawasaki KLX 250 motorcycle.

Estimated Page Count:

400-600

Manual Classification:

Service Workshop Repair Manual

Primary Language:

English

Digital Format:

PDF (Downloadable)

📖 Manual Coverage

Engine System:

Complete engine overhaul, including disassembly, inspection, assembly, valve adjustment, timing, and component diagnostics.

Fuel System:

Carburetor (or Fuel Injection system depending on variant) tuning, cleaning, and repair; fuel pump, lines, and tank maintenance.

Cooling System:

Radiator, fan, coolant flow, and hose inspection and replacement.

Ignition System:

Spark plugs, ignition coils, CDI unit, and troubleshooting.

Exhaust System:

Muffler, header pipe, and catalytic converter (if applicable) inspection and replacement.

Transmission System:

Clutch operation, gear shifting mechanism, transmission overhaul, and lubricant specifications.

Drivetrain:

Chain and sprockets maintenance, adjustment, and replacement; rear swingarm and linkage lubrication and inspection.

Suspension System:

Front fork (telescopic) and rear shock absorber servicing, oil changes, seal replacement, and adjustment.

Braking System:

Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, and disc inspection.

Wheel And Tire System:

Wheel bearing inspection and replacement, spoke tension adjustment, tire mounting and balancing, and recommended tire pressures.

Electrical System:

Battery, charging system (stator, regulator/rectifier), lighting, starter motor, and wiring diagrams.

Frame And Bodywork:

Frame inspection, body panel removal and installation, seat, fuel tank, and handlebar servicing.

Maintenance Procedures:

Routine maintenance checks, oil changes, filter replacements, chain lubrication, brake adjustments, and general inspection.

Diagnostic Procedures:

Troubleshooting guides for common problems, electrical system diagnostics, and engine performance issues.

Repair Procedures:

Step-by-step instructions for component removal, replacement, and repair across all major systems.

Overhaul Procedures:

Detailed guides for complete engine and transmission overhauls.

Assembly Disassembly:

Complete instructions for dismantling and reassembling the motorcycle and its components.

Depth Of Coverage:

Advanced; suitable for experienced DIY mechanics and professional technicians.

Diagnostic Capabilities:

Includes symptom-based troubleshooting charts and specific diagnostic tests.

Tightening Torques:

Specific torque values for all critical fasteners and bolts.

Clearances:

Detailed specifications for valve clearances, piston ring gaps, and other critical component clearances.

Wiring Diagrams:

Comprehensive, color-coded electrical wiring diagrams.

📊 Manual Specifications

Digital Format Details:

Searchable PDF with high-resolution images and diagrams.

Image Resolution:

High resolution, suitable for screen viewing and targeted printing.

Physical Binding If Applicable:

N/A (Digital PDF)

Physical Paper Type If Applicable:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Four-stroke, DOHC, single-cylinder

Displacement:

249 cc (249 cm³)

Bore X Stroke:

72.0 mm x 61.2 mm (typical)

Cooling System:

Liquid-cooled

Horsepower:

Approx. 22-27 hp (varies by year and market)

Torque:

Approx. 18-20 Nm (varies by year and market)

Fuel Delivery:

Carburetor (e.g., Keihin CVK34) or Electronic Fuel Injection (EFI) depending on model year/variant.

Fuel Type:

Unleaded gasoline

🔧 Transmission

Transmission Type:

Constant mesh 6-speed

Clutch Type:

Wet, multi-disc

Gear Ratios:

Detailed in manual for specific model variants.

📐 Dimensions

Length:

Approx. 2,180 mm (varies)

Width:

Approx. 800 mm (varies)

Height:

Approx. 1,170 mm (varies)

Wheelbase:

Approx. 1,430 mm (varies)

Curb Weight:

Approx. 130-138 kg (varies)

Fuel Tank Capacity:

Approx. 7.7 L - 11 L (varies by generation/market)

🛡️ Safety Features

Safety Certification:

Meets relevant motorcycle safety standards for production markets.

Braking System Type:

Disc brakes front and rear. ABS available on some later models.

Lighting System:

Halogen or LED headlight, tail light, and turn signals.

💡 Technology Features

Instrument Cluster:

Digital LCD display with speedometer, tachometer, odometer, trip meter, fuel gauge, clock, and indicator lights.

ABS Availability:

Available on select later model years (e.g., KLX250 ABS).

Connectivity Features:

None (basic motorcycle design).

🔧 Maintenance

Oil Change Interval:

Every 3,000-6,000 km or 6-12 months (refer to manual for specific model year).

Valve Adjustment Interval:

Every 6,000-12,000 km (refer to manual).

Chain Maintenance:

Lubrication and tension check every 500-1,000 km.

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified (verify in manual).

Coolant Type:

Permanent type ethylene glycol based coolant (50% solution with distilled water).

Brake Fluid Type:

DOT 4 (verify in manual).

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals.

Potential Engine Concerns:

Valve seat wear (rare), carburetor jetting issues (on older models) if not properly maintained.

📚 Vehicle History

Manufacturer:

Kawasaki Heavy Industries Motorcycle & Engine Company

Key Generations:

The KLX 250 has seen several iterations, notably the early carbureted models and later fuel-injected versions with updated styling and features (e.g., KLX250S, KLX250SF, KLX250). The manual covers specific variants which should be confirmed by the user.

Production Period:

Continuously produced since the 1990s, with significant updates in the 2000s and beyond.