Target Audience:
Owners of the 1995 Kawasaki KLX250 D3 seeking to perform maintenance and repairs themselves, as well as independent repair shops.
Market Niche:
Compact dual-sport motorcycle known for its off-road capability and manageable power for its era.
Competitors Era:
Honda XR250L, Yamaha XT225, Suzuki DR250SE.
Klx250 Era Appeal:
Reliable liquid-cooled engine, capable suspension for varied terrain, user-friendly power delivery.
Engine Systems:
Engine overhaul, disassembly, assembly, cylinder head, piston, crankshaft, lubrication system, cooling system (liquid-cooled), valve train.
Fuel System:
Carburetor (Keihin CVK34), fuel pump, fuel tank, fuel lines, fuel filter.
Ignition System:
CDI ignition system, spark plugs, ignition coils, timing.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox overhaul, gear selection, chain drive maintenance, sprocket inspection.
Chassis Suspension:
Front fork (upside-down telescopic), rear shock absorber (Uni-Trak), swingarm, bearings, steering head.
Braking System:
Front disc brake, rear disc brake, hydraulic system, caliper overhaul, pad replacement, fluid bleeding, master cylinder.
Electrical System:
Wiring diagrams, battery, starter motor, charging system (stator, regulator/rectifier), lighting (headlight, taillight, turn signals), instrumentation, fuses.
Exhaust System:
Muffler, exhaust pipes, heat shields, inspection and replacement.
Bodywork Frame:
Frame inspection, fuel tank removal/installation, seat, fenders, side covers, handlebars, levers.
Maintenance Procedures:
Oil changes, filter replacement, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake inspection and adjustment, fluid level checks.
Troubleshooting Guides:
Diagnostic charts for common problems, electrical troubleshooting flowcharts, engine performance issues, starting problems.
Repair Procedures:
Complete engine rebuild, carburetor tuning and rebuilding, fork seal replacement, shock absorber servicing, brake caliper overhaul, wheel bearing replacement, electrical component testing.
Component Disassembly Assembly:
Step-by-step instructions for disassembling and reassembling all major motorcycle components.
Diagnostic Capabilities:
Advanced diagnostics including ignition timing checks, carburetor jetting analysis, compression testing, and electrical system resistance checks.
Rebuild Specifications:
Detailed specifications for engine component clearances, torque values, and rebuild procedures for a complete overhaul.
Service Manual Scope:
Covers routine maintenance to complete mechanical and electrical repairs.
Engine Type:
Four-stroke, DOHC, 4-valve, Single Cylinder
Displacement:
249 cc (249 cm³)
Bore X Stroke:
72.0 mm x 61.2 mm
Cooling System:
Liquid-Cooled
Compression Ratio:
10.0:1
Horsepower Est:
Approximately 29-32 HP @ 7500 RPM (specification dependent on tuning and market).
Torque Est:
Approximately 25-27 Nm @ 6000 RPM (specification dependent on tuning and market).
Carburetor Model:
Keihin CVK34 (Constant Velocity)
Fuel Type:
Unleaded Gasoline
Oil Capacity Est:
Approximately 1.6 Liters (with filter change).
Oil Grade Recommendation:
10W-40 or 20W-50 API SG or SH (refer to manual for specific viscosity based on ambient temperature).
Safety Rating Overview:
Motorcycles typically do not receive formal crash ratings like cars. Safety is dependent on rider skill and adherence to maintenance.
Braking System Type:
Hydraulic disc brakes front and rear for effective stopping power.
Suspension Design:
Upside-down front forks and Uni-Trak rear suspension provide stability and control on varied surfaces.
Lighting System:
Halogen headlight, taillight, and brake lights for visibility.
Ergonomics:
Designed for a comfortable riding posture suitable for both on-road and off-road use.
Infotainment System:
N/A (Basic motorcycle instrumentation).
Driver Assistance Features:
N/A (No electronic rider aids common to modern vehicles).
Connectivity Features:
N/A.
Dashboard Components:
Speedometer, odometer, trip meter, engine temperature gauge (if applicable), indicator lights (turn signal, oil pressure, high beam).
Engine Oil Change Interval:
Every 3,000 km (1,860 miles) or 6 months, whichever comes first (refer to manual for exact interval).
Oil Filter Change Interval:
At every oil change.
Air Filter Cleaning Interval:
Every 1,000 km (620 miles) or more frequently in dusty conditions.
Chain Maintenance Interval:
Lubricate and adjust chain every 500 km (310 miles) or as needed.
Spark Plug Replacement Interval:
Approximately 10,000 km (6,200 miles) (refer to manual for specific type and gap).
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio recommended).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Carburetor Idling Instability:
Can sometimes experience slightly rough idling; requires proper carburetor cleaning and adjustment.
Fork Seal Leaks:
Like many motorcycles of this era, front fork seal leaks can occur over time and mileage, requiring replacement.
Clutch Cable Adjustment:
Clutch cable stretch can lead to lever play issues; regular adjustment is recommended.
Parts Catalogue Reference
Oem Part Number Example:
Specific OEM part numbers for common consumables (e.g., oil filters, brake pads) will be detailed within the manual.
Kawasaki Motorsports Legacy:
Kawasaki has a long and storied history in motorsports, particularly in off-road and motocross disciplines, which informs the design and engineering of the KLX series.
Klx Series Development:
The KLX line has evolved significantly over the years, with the KLX250 being a staple in Kawasaki's dual-sport offerings, known for its versatility and off-road prowess.
Klx250 D Series:
The 'D' series, including the D3, represents a generation of the KLX250 that solidified its reputation as a capable and relatively lightweight dual-sport machine.
Production Era:
The KLX250 was in production for many years, with the D3 model belonging to the mid-1990s iteration.
Manufacturing Location Est:
Primarily manufactured in Japan by Kawasaki Heavy Industries.
