Target Audience:
DIY motorcycle enthusiasts, independent repair shops, Kawasaki KLX250/300 owners seeking to perform their own maintenance and repairs.
Value Proposition:
Provides comprehensive, factory-level technical information essential for maintaining and repairing the 1997 Kawasaki KLX250/300, enabling cost savings through self-service.
Completeness:
Extremely detailed, covering all workshop procedures and technical data.
Accessibility:
PDF format allows for easy access, searching, and selective printing of required sections.
Engine Mechanical:
Full engine disassembly, inspection, repair, and reassembly including: cylinder head, pistons, crankshaft, connecting rods, valve train, timing, lubrication system, cooling system (if applicable).
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel delivery system components.
Ignition System:
Ignition timing, spark plugs, ignition coil, CDI unit, troubleshooting.
Injection System:
While the description mentions 'Injection-Ignition/Injection System', for the 1997 KLX250/300 this likely refers to the ignition system and potentially early electronic fuel injection diagnostics if applicable to certain export models or variations. Primary focus for this era is carburetion.
Clutch System:
Clutch operation, inspection, adjustment, replacement of clutch plates and springs.
Transmission System:
Gearbox disassembly, inspection, repair, shift mechanism, lubrication.
Suspension System:
Front fork (telescopic, cartridge type) overhaul, seal replacement, oil levels, damping adjustments; rear shock absorber inspection and adjustment.
Wheel And Tire System:
Wheel bearing maintenance, spoke tensioning (if applicable), tire mounting and balancing, wheel alignment.
Braking System:
Front and rear disc brake inspection, caliper service, pad replacement, fluid bleeding, master cylinder overhaul.
Electrical System:
Wiring diagrams, lighting system, starting system (starter motor, battery), charging system (alternator, regulator/rectifier), fuses, switches, troubleshooting.
Bodywork And Frame:
Fairings, fenders, fuel tank, seat, frame inspection, handling components.
Air Temperature Control:
This section is unusual for a 1997 dirt bike. It may refer to engine intake air temperature sensors or ambient air temperature readings for performance tuning, or it might be a misinterpretation of a system like the engine cooling (air-cooled or liquid-cooled) or a very specific emissions control system. Given the era and model, it's most likely related to engine intake air management.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication, spark plug checks, air filter cleaning/replacement.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults across all covered systems.
Repair And Rebuild:
Detailed, step-by-step instructions for component repair and full system overhauls (e.g., engine rebuild, suspension fork rebuild, brake caliper overhaul).
Adjustment Procedures:
Carburetor adjustment, clutch adjustment, brake lever adjustment, suspension pre-load adjustments.
Specifications And Data:
Torque specifications, fluid capacities, electrical specifications, engine component tolerances, recommended maintenance intervals.
Depth:
Comprehensive - covers everything from basic servicing to complete engine and component rebuilds, including detailed diagnostic information.
Diagrams And Illustrations:
Detailed step-by-step diagrams, exploded views, and clear illustrations for all procedures.
Engine Type:
4-stroke, DOHC, single-cylinder (typically liquid-cooled on KLX300, air-cooled on some KLX250 variants of that era - manual covers both).
Displacement:
249cc (KLX250), 292cc (KLX300) - Manual covers both variants.
Bore X Stroke:
KLX250: 72.0 x 61.2 mm; KLX300: 78.0 x 61.2 mm (typical specifications for this generation)
Compression Ratio:
Varies by specific model variant, typical around 10.0:1 to 11.0:1. Manual will specify exact figures.
Horsepower Output:
KLX250: Approx. 25-30 HP; KLX300: Approx. 30-35 HP (at the crank, manufacturer dependent). Manual provides exact figures.
Torque Output:
Refer to manual for specific torque figures, typically in the 18-22 lb-ft range for KLX250 and higher for KLX300.
Fuel Delivery:
Carburetor (e.g., Keihin CVK34 for KLX250, potentially larger for KLX300). Manual details specific carburetor models and tuning.
Fuel Type:
Unleaded gasoline, typically 87 octane or higher. Manual will specify minimum octane rating.
Engine Oil Change:
Typically every 3,000 km (1,860 miles) or 6 months, but manual provides precise intervals.
Air Filter Cleaning:
Regular checks and cleaning, typically every 1,000-2,000 km (620-1,240 miles) or as conditions dictate. Manual specifies exact intervals and cleaning procedures.
Spark Plug Inspection:
Typically every 3,000-5,000 km (1,860-3,100 miles). Manual provides specific replacement intervals and plug type.
Chain Lubrication And Adjustment:
Recommended every 500-1,000 km (310-620 miles) or after riding in wet conditions. Manual details tension specifications.
Engine Oil Type And Capacity:
Typically SAE 10W-40 or 20W-50 API SG or higher. Capacity around 1.7-1.9 liters (with filter). Manual specifies exact grade and capacity.
Brake Fluid Type:
DOT 3 or DOT 4. Manual specifies exact type and replacement interval.
Fork Oil Type And Viscosity:
Typically SAE 10W fork oil. Capacity per leg around 300-350 ml. Manual specifies exact type and level.
Carburetor Performance:
Age-related degradation of rubber components (e.g., diaphragm in CV carburetors) can affect performance. Manual covers carburetor overhaul and troubleshooting.
Suspension Seals:
Front fork seal leaks can occur over time due to wear. Manual details fork seal replacement procedures.
Cooling System Hoses:
For liquid-cooled models (KLX300), rubber hoses can degrade and crack with age, leading to leaks. Manual covers cooling system inspection and maintenance.
