Market Segment:
Dual-sport motorcycle, targeting riders seeking versatility for on-road and off-road use.
Competitors:
Honda XR250L, Yamaha XT225/XT350, Suzuki DR250/DR350.
Key Features Vehicle:
Lightweight chassis, capable off-road suspension, user-friendly engine, reliable performance.
Key Features Manual:
Detailed technical information, clear diagrams, comprehensive troubleshooting guides, essential for maintenance and repair.
Engine:
Engine assembly, disassembly, overhaul, tuning, lubrication, cooling system, fuel system, ignition system, exhaust system, piston, cylinder, crankshaft, camshaft, valves.
Transmission:
Clutch, gearbox, gearshift mechanism, internal components, lubrication, maintenance, adjustments.
Chassis:
Frame, suspension (front forks, rear shock absorber), steering system, wheels, tires, bearings, swingarm.
Brakes:
Front and rear brake systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, pad replacement, caliper overhaul, master cylinder.
Electrical System:
Wiring diagrams, lighting, ignition system, charging system (stator, regulator/rectifier), starter motor, battery, fuses, switches, sensors.
Fuel System:
Carburetor (model and type specific), fuel pump, fuel filter, fuel lines, tank.
Exhaust System:
Muffler, exhaust pipe, heat shields, mounting hardware.
Bodywork:
Fairings, fenders, seat, fuel tank, body panels, graphics, fasteners.
Maintenance:
Routine inspections, oil changes, filter replacements, chain adjustment, brake fluid flush, coolant flush, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnosis of common problems, symptom identification, fault finding procedures for engine, electrical, and mechanical systems.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major systems.
Rebuilds:
Comprehensive guidance on engine rebuilds, carburetor overhauls, and suspension component refurbishment.
Adjustments:
Carburetor tuning, ignition timing, clutch adjustment, brake lever adjustment, suspension settings.
Specifications Torque:
Torque specifications for all critical fasteners and components.
Depth:
Comprehensive coverage from basic maintenance to complete engine and chassis overhauls, suitable for both novice mechanics and experienced technicians.
Engine Type:
4-stroke, DOHC, 4-valve, Single Cylinder
Displacement:
249 cc (249 cubic centimeters)
Bore X Stroke:
Approximately 72.0 mm x 61.2 mm (verify exact spec for the period).
Cooling System:
Liquid-cooled
Compression Ratio:
Typically around 10.0:1 to 11.0:1 (verify exact spec).
Horsepower:
Estimated 28-32 HP (at crank, subject to tuning and specific model year).
Torque:
Estimated 2.3-2.5 kg-m (at crank, subject to tuning and specific model year).
Carburetor:
Single Mikuni VM Series carburetor (e.g., VM28SS or similar, specific model may vary).
Fuel Type:
Unleaded gasoline
Oil Type:
API SG, SAE 10W-40 or 10W-50 motorcycle specific oil (verify manual for exact recommendations).
Oil Capacity:
Approx. 1.6 - 1.8 liters (with filter change, verify exact spec).
Overall Length:
Approximately 2200 mm (verify exact spec).
Overall Width:
Approximately 820 mm (verify exact spec).
Overall Height:
Approximately 1185 mm (verify exact spec).
Wheelbase:
Approximately 1430 mm (verify exact spec).
Ground Clearance:
Approximately 250-270 mm (verify exact spec).
Dry Weight:
Approximately 120-125 kg (verify exact spec).
Curb Weight:
Approximately 130-135 kg (with fluids, verify exact spec).
Fuel Tank Capacity:
Approximately 11 liters (including reserve, verify exact spec).
Oil Change Interval:
Every 3,000-5,000 km or 6-12 months (refer to manual for exact recommendation).
Chain Maintenance:
Check and lubricate chain every 500-1000 km; adjust tension as needed.
Air Filter Cleaning:
Clean every 3,000-6,000 km, replace as needed (more frequent in dusty conditions).
Spark Plug Replacement:
Inspect every 5,000-10,000 km, replace as needed. Consult manual for recommended plug type and gap.
Brake Fluid Flush:
Every 2 years or as per manual recommendation.
Engine Oil Grade:
SAE 10W-40 or 10W-50, API SG or higher, JASO MA approved.
Brake Fluid Type:
DOT 4 or DOT 5.1 (verify manual for specific requirement).
Coolant Type:
Ethylene glycol-based coolant, 50/50 mixture with distilled water.
Common Issues:
Carburetor jetting sensitivity to altitude/temperature, potential for clutch wear with aggressive use, fork seal leaks, occasional electrical connector corrosion.
Kawasaki Heritage:
Kawasaki Heavy Industries, Ltd. is a Japanese public multinational corporation manufacturer of motorcycles, engines, heavy equipment, aerospace and defense equipment, electronics, trains and other vehicles. Known for its performance-oriented motorcycles.
Klx Lineage:
The KLX250 is part of Kawasaki's long-standing dual-sport line, known for its off-road capability and street legality. It evolved from earlier models like the KLR250, offering a more performance-oriented package.
Production Period:
The KLX250 model range has been in continuous production for many years, with significant updates and variations across different generations. This specific manual covers the models from 1993 to 1997.
