Category:
Dual-sport motorcycle
Target Audience:
Owners and independent mechanics of the 1996 Kawasaki KLX250-D4.
Competitors 1996:
Honda XR250L, Yamaha WR250, Suzuki DR250SE.
Vehicle Strengths:
Off-road capability, reliability, relatively simple mechanics for its era.
Value Proposition:
Essential resource for maintaining and repairing the specific KLX250-D4 model, ensuring longevity and optimal performance.
Engine:
Complete engine disassembly, assembly, tuning, and diagnostics.
Fuel System:
Carburetor service, adjustments, fuel tank, fuel lines, and fuel pump (if applicable).
Ignition System:
Ignition timing, spark plug specifications, CDI unit, and troubleshooting.
Cooling System:
Radiator, coolant, cooling fan, and related components.
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism.
Suspension:
Front fork overhaul, rear shock absorber inspection and service, linkage components.
Brakes:
Front and rear brake system inspection, hydraulic fluid, caliper service, pad replacement, disc inspection.
Electrical System:
Wiring diagrams, battery, lighting, starter system, charging system, fuses, relays.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank mounting.
Wheels And Tires:
Tire specifications, wheel bearing service, spoke tensioning (if applicable).
Routine Maintenance:
Oil change intervals, filter replacement, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic charts for common problems, symptom-to-cause analysis.
Repair Procedures:
Step-by-step instructions for major component overhauls and repairs.
Disassembly Assembly:
Detailed instructions for taking apart and reassembling all major systems.
Adjustments:
Carburetor, clutch, throttle, and suspension adjustments.
Depth:
Comprehensive; covers basic maintenance to complete engine and chassis rebuilds.
Digital Format:
PDF (most common for scanned factory manuals)
Scan Resolution:
High-resolution scans ensuring clarity of diagrams and text.
Binding:
N/A (for digital); if physical, typically bound for durability.
Paper Quality:
N/A (for digital); original factory manuals used durable paper.
Estimated Page Count:
Approximately 300-400 pages (typical for this era's factory service manuals)
Engine Type:
Four-stroke, liquid-cooled, DOHC, single-cylinder
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Horsepower Estimated:
Approximately 29 hp @ 8500 rpm (factory figures vary by region)
Torque Estimated:
Approximately 2.4 kgf·m @ 7000 rpm (factory figures vary by region)
Fuel Capacity:
9.5 Liters (2.5 US gal)
Cooling Method:
Liquid-cooled
Crash Safety Ratings:
N/A (Motorcycle safety is assessed through different standards than automobiles).
Braking System Type:
Hydraulic disc brakes front and rear.
Lighting:
Headlight, taillight, brake lights, turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame.
Infotainment System:
N/A (Basic instrumentation: speedometer, odometer, trip meter, indicator lights).
ABS:
N/A (ABS was not a standard feature on this model).
Connectivity Features:
N/A (No electronic connectivity features).
Engine Oil Change:
Every 3,000 km (1,860 miles) or 6 months, whichever comes first (refer to manual for precise interval).
Oil Filter Replacement:
Replace at every oil change.
Air Filter Cleaning:
Inspect every 3,000 km (1,860 miles), clean/replace as needed.
Spark Plug Replacement:
Inspect every 6,000 km (3,720 miles), replace as needed.
Chain Adjustment:
Inspect and adjust chain slack every 1,000 km (620 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher (check manual for specific viscosity range based on temperature).
Engine Oil Capacity:
1.9 Liters (2.0 US qt) without filter change, 2.1 Liters (2.2 US qt) with filter change.
Coolant Type:
Ethylene glycol based anti-freeze and soft water mixture (50:50 ratio).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, fork seals, wheel bearings, carburetor jets can wear over time.
Carburetor Tuning:
May require occasional fine-tuning or cleaning due to age and usage, especially in varied altitudes.
Cooling System Maintenance:
Regular coolant flushes and checking for leaks are crucial to prevent overheating.
Manufacturer:
Kawasaki Heavy Industries, Motorcycle & Engine Company.
Heritage Focus:
Known for performance motorcycles, from street bikes to off-road and motocross models.
Klx Lineage:
The KLX line has a long history of off-road and dual-sport capabilities, evolving from earlier models like the KLR.
Klx250 Development:
Introduced as a capable dual-sport, balancing off-road prowess with street legality.
Production Period:
The KLX250 model has seen various iterations and updates throughout the late 20th and early 21st centuries.
Manufacturing Origin:
Likely Japan (common for Kawasaki during this period).
