🏷️ Basic Information

Make:

Kawasaki

Model:

KLR250

Generation:

A1-A15, B1-B2 (1984-2005)

Engine Type:

Four-stroke, single-cylinder

Motorcycle Class:

Dual-sport, Enduro

👋 Introduction

Segment:

Entry-level to mid-weight dual-sport motorcycle, known for its ruggedness and reliability.

Competitors:

Honda XR250L, Suzuki DR250SE, Yamaha XT225/XT350.

Design Philosophy:

Versatile dual-purpose machine capable of on-road commuting and off-road exploration, emphasizing simplicity and durability.

Platform Basis:

Shares lineage and some components with the KLR600, but tailored for the 250cc class.

📋 Manual Details

Covered Years:

1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Geographic Coverage:

Global (Based on factory specifications)

Page Count:

285 pages

Manual Type:

Service Repair Manual (Factory Based)

Language:

English

Format:

PDF (Downloadable)

File Delivery:

Instant Download

📖 Manual Coverage

Engine Management:

Engine overhaul, top-end rebuild, bottom-end rebuild, valve clearance adjustment, carburetor tuning (main jet, pilot jet, mixture screw), ignition system, starting system, lubrication system, cooling system (radiator, coolant flush/change), fuel system (fuel pump, fuel tank, lines).

Drivetrain:

Transmission overhaul and repair, clutch operation and adjustment, drive train maintenance, primary reduction gear, drive shaft, sprockets, chain maintenance.

Chassis And Suspension:

Front fork service (oil change, seal replacement, adjustments), rear shock absorber maintenance, swingarm service, wheel bearing replacement, steering head bearing service, frame inspection and repair.

Braking System:

Front and rear brake system service, caliper overhaul, brake pad replacement, brake fluid flush and replacement, rotor inspection.

Electrical Components:

Ignition system diagnosis (coil, spark plug), charging system (stator, regulator/rectifier), battery maintenance, lighting system, starter motor, wiring diagrams, troubleshooting electrical problems (no spark).

Body Panels:

Fender removal and installation, plastic component service, seat removal, handlebar replacement.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, brake fluid checks, tire pressure checks, coolant level checks, spark plug replacement.

Troubleshooting:

Comprehensive troubleshooting guides for common issues, including starting problems, engine performance issues, electrical faults, and braking system concerns.

Repair And Rebuild:

Detailed step-by-step instructions for complete engine tear-down and rebuild, transmission overhauls, suspension rebuilds, and brake system repairs.

Technical Specifications:

Torque specifications for all fasteners, fluid capacities, viscosity recommendations, engine timing, valve clearances, bore and stroke dimensions.

Depth Of Coverage:

Complete factory-level repair and maintenance information, suitable for both novice DIY enthusiasts and professional technicians.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text for easy information retrieval.

Printability:

Printable without restrictions.

Zoomability:

Zoomable illustrations and diagrams.

Illustration Quality:

Clear, step-by-step illustrated instructions, pictures, and part diagrams.

File Size Consideration:

Can be large (up to 5GB), requires adequate storage space and internet connection.

Software Requirements:

PDF reader; WinZip or WinRAR for zipped files.

Authenticity:

Original Kawasaki factory-based manual, also includes KLR600 base manual with KLR250 supplement.

⚙️ Engine Specifications

Engine Type:

4-stroke, single-cylinder, DOHC, 4 valves

Displacement:

249 cc (249 cubic centimeters)

Bore X Stroke:

70.0 mm x 64.5 mm

Compression Ratio:

9.8:1 (typical, may vary slightly by year)

Horsepower:

Approx. 25-30 HP (at crankshaft, varies by year and tuning)

Torque:

Approx. 15-18 lb-ft (at crankshaft, varies by year)

Fuel Delivery:

Carburetor (e.g., Keihin CVK32)

Fuel Type:

Unleaded gasoline

Cooling Method:

Liquid-cooled

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-disc

Drive Type:

Chain drive

📐 Dimensions

Length:

Approx. 2,185 mm (86.0 in)

Width:

Approx. 820 mm (32.3 in)

Height:

Approx. 1,160 mm (45.7 in)

Wheelbase:

Approx. 1,435 mm (56.5 in)

Dry Weight:

Approx. 124 kg (273 lbs)

Wet Weight:

Approx. 137 kg (302 lbs) (with all fluids)

Fuel Tank Capacity:

Approx. 10.5 Liters (2.8 US gal)

🛡️ Safety Features

Crash Safety:

Not applicable to motorcycles in the same way as cars; relies on rider protection and vehicle dynamics.

Handling Stability:

Designed for stable handling on varied terrain.

Lighting:

Headlight, taillight, turn signals for visibility.

💡 Technology Features

Infotainment System:

Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator.

Electronic Aids:

No electronic rider aids (e.g., ABS, traction control) present on this model.

Connectivity Features:

N/A

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 km (1,800-3,000 miles) or 6 months, refer to manual for specifics.

Valve Clearance Check:

Recommended every 10,000-15,000 km (6,000-9,000 miles), refer to manual for exact interval.

Spark Plug Replacement:

Refer to manual, typically at 10,000-15,000 km intervals.

Engine Oil Type:

API SE, SF, SG or SH, JASO MA, SAE 10W-40 or 20W-50 recommended. Consult manual for precise viscosity based on ambient temperature.

Coolant Type:

Permanent type ethylene glycol based coolant (e.g., Kawasaki Coolant KLC or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 recommended.

Common Problems:

Carburetor clogging due to infrequent use, potential cam chain noise, fork seal leaks, starter clutch wear (on some models).

Preventative Measures:

Regular cleaning of carburetor, consistent oil changes, checking for fluid leaks, periodic chain adjustment.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries has a long history of manufacturing motorcycles, known for performance and innovation across various segments.

Klr Lineage:

The KLR series, including the KLR250 and KLR600/650, represents Kawasaki's commitment to durable, versatile dual-sport motorcycles.

Production Period:

1984-2005 (as indicated by manual coverage).

Manufacturing Location:

Japan

🏆 Awards & Recognition

Market Perception:

Generally well-regarded for its robustness, affordability, and versatility in the dual-sport market.

Durability:

Many KLR250s remain on the road with high mileage, testament to their solid engineering.