Positioning:
The KLX250 series was positioned as a capable dual-sport motorcycle, suitable for both on-road commuting and off-road trail riding, bridging the gap between pure dirt bikes and street-oriented motorcycles.
Competitors:
Competed against models such as the Yamaha XT250, Honda XR250L, and Suzuki DR250S of the era.
Features Vehicle:
Liquid-cooled, four-stroke engine; capable suspension for varied terrain; dual-sport tires; street-legal equipment.
Value:
Provides owners and mechanics with the definitive guide for maintaining, troubleshooting, and repairing their 1993 Kawasaki KLX250/KLX250R, ensuring longevity and optimal performance.
Coverage:
Complete repair, service, and maintenance for the 1993 Kawasaki KLX250 and KLX250R models.
Pages:
Estimated 300+ pages (typical for a comprehensive service manual of this era).
Type:
Factory-authorized Repair Service Manual.
Engine:
Detailed diagnostics, disassembly, inspection, repair, and reassembly of the engine (including top-end, bottom-end, lubrication system, cooling system).
Fuel System:
Carburetor adjustment, overhaul, troubleshooting, fuel tank, fuel lines.
Transmission Drivetrain:
Clutch operation, transmission gear inspection and replacement, final drive (chain and sprockets).
Suspension:
Front fork (telescopic) disassembly, service, and adjustment; rear shock absorber service and linkage lubrication.
Brakes:
Front and rear brake system inspection, hydraulic line service, pad replacement, caliper overhaul.
Electrical System:
Ignition system, lighting system, charging system (stator, regulator/rectifier), battery maintenance, starter motor, wiring diagrams.
Chassis Bodywork:
Frame inspection, handlebar, footpegs, seat, body panels, fender replacement.
Maintenance:
Regular maintenance checks, oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning.
Troubleshooting:
Systematic diagnostic procedures for common performance issues and malfunctions.
Repair:
Step-by-step repair instructions for all major mechanical and electrical components.
Rebuilds:
Comprehensive instructions for complete engine and carburetor rebuilds.
Adjustments:
Valve clearance adjustment, ignition timing checks, carburetor synchronization and jetting adjustments.
Depth:
Expert-level, covering complete disassembly, component inspection, measurement, repair, and reassembly for all systems.
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder.
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Horsepower:
Approximately 27-30 HP (specifications varied slightly by region and tuning).
Torque:
Approximately 18-20 lb-ft (specifications varied slightly by region and tuning).
Carburetor:
Keihin CVK34 (Constant Velocity Keihin).
Fuel Type:
Unleaded gasoline, 87-90 octane.
Oil Type Specification:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Oil Capacity:
1.7 L (1.8 US qt) with filter change.
Length:
Approx. 2,145 mm (84.4 in)
Width:
Approx. 820 mm (32.3 in)
Height:
Approx. 1,205 mm (47.4 in)
Dry Weight:
Approx. 121 kg (267 lbs)
Wet Weight:
Approx. 131 kg (289 lbs) (estimated with fluids).
Front Suspension Travel:
280 mm (11.0 in) (Telescopic fork).
Rear Suspension Travel:
260 mm (10.2 in) (Uni-Trak single shock).
Front Tire:
80/100-21 M/C 51P
Rear Tire:
100/100-18 M/C 59P
Crash Safety Ratings:
N/A (Motorcycles are not rated under automotive crash test standards like NHTSA or Euro NCAP).
Braking System:
Front: Disc brake. Rear: Disc brake.
Lighting:
Headlight, taillight, brake light, turn signals (street-legal variants).
Infotainment System:
N/A (Analog gauges: speedometer, tachometer, odometer, trip meter, engine temperature warning light, neutral indicator).
Driver Assistance Features:
N/A (Motorcycle of this era).
Connectivity Options:
N/A (Motorcycle of this era).
Oil Change Interval:
Every 3,000 km (2,000 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed based on riding conditions.
Spark Plug Replacement:
Every 6,000 km (4,000 miles).
Valve Clearance Check:
Every 6,000 km (4,000 miles).
Coolant Type:
Permanent type antifreeze/coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, and exhaust system components are common wear items on dual-sport motorcycles of this age.
Potential Carburetor Issues:
Carburetor can be prone to gumming up if fuel is left in the system for extended periods without stabilizer; requires regular cleaning and adjustment.
Kawasaki Heritage:
Kawasaki has a long-standing history in motorcycle manufacturing, particularly in performance-oriented machines and off-road vehicles.
Klx Lineage:
The KLX series has evolved significantly, with the KLX250 being a staple in Kawasaki's dual-sport lineup, known for its versatility and off-road capability. The 'R' designation often signified a more performance-oriented or competition-focused version.
Production Era:
The KLX250 line has been in continuous production in various forms since the late 1970s, with the 1993 model representing a specific iteration of this popular dual-sport platform.
