Target User:
Do-it-yourself owners and experienced mechanics.
Value Proposition:
Provides professional, dealership-level repair information at a fraction of the cost of professional service.
Usability:
Step-by-step instructions and detailed exploded diagrams for efficient and correct repairs.
Accessibility:
Instant download access, no shipping delays.
Portability:
Digital format allows for use on smartphones for on-the-trail repairs.
Engine:
Complete overhaul, troubleshooting, diagnostics, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system.
Transmission:
Clutch operation and adjustment, gear shifting mechanism, internal transmission components inspection and repair.
Chassis:
Frame, suspension (front forks, rear shock absorber), steering system, wheel bearings, swingarm.
Brakes:
Front and rear brake systems (disc and drum), hydraulic components, pad/shoe replacement, bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system components, lighting, instrumentation.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable).
Bodywork:
Fairing, seat, fuel tank, fenders, side covers, mounting hardware.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, brake adjustments, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Systematic diagnosis of common problems, fault finding charts, symptom-based troubleshooting.
Repair:
Detailed step-by-step instructions for component disassembly, repair, and reassembly.
Disassembly Reassembly:
Full breakdown and rebuild procedures for all major vehicle systems.
Depth:
Comprehensive; covers everything from basic adjustments to full engine rebuilds and complex electrical troubleshooting.
Diagnostic Tools:
Includes specifications for required special tools and diagnostic procedures.
Engine Type:
4-stroke, DOHC, single cylinder
Displacement:
249 cc (15.2 cu in)
Bore X Stroke:
70.0 x 64.5 mm (2.76 x 2.54 in)
Horsepower:
Approximately 26-28 hp (varies slightly by region and specific tuning)
Torque:
Refer to manual for exact figures; typically around 16-18 lb-ft.
Carburetor:
Mikuni VM28SS or similar single carburetor.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual).
Cooling Method:
Liquid-cooled
Oil Type:
Refer to manual for specific SAE viscosity grade and API classification (e.g., SAE 10W-40 API SG).
Oil Capacity:
Refer to manual for exact capacity with filter change (typically around 1.7 - 2.0 liters).
Overall Length:
Refer to manual; typically around 2180 mm (85.8 in)
Overall Width:
Refer to manual; typically around 830 mm (32.7 in)
Overall Height:
Refer to manual; typically around 1165 mm (45.9 in)
Dry Weight:
Approximately 136 kg (300 lbs)
Curb Weight:
Refer to manual; typically around 149 kg (328 lbs)
Fuel Tank Capacity:
17 Liters (4.5 US gal)
Safety Standards:
Adheres to manufacturing standards of its era; manual provides safety precautions for operation and maintenance.
Braking System:
Front disc brake, Rear drum brake (for optimal stopping power and modulation).
Lighting:
Headlight, taillight, brake light, turn signals for visibility.
Construction:
Sturdy frame and bodywork design for rider protection.
Oil Change Interval:
Refer to manual; typically every 3,000-5,000 km (1,800-3,000 miles) or annually.
Chain Lubrication Adjustment:
Frequent checks and lubrication recommended, especially under off-road conditions (every 500-1000 km).
Air Filter Cleaning:
Recommended every 3,000-6,000 km, depending on operating conditions.
Valve Clearance Check:
Refer to manual; typically around 6,000-12,000 km or as needed based on performance.
Coolant Type:
Ethylene glycol based antifreeze coolant (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, brake pads/shoes due to age and use.
Carburetor Performance:
Can be prone to gumming up if fuel sits for extended periods; requires regular cleaning and adjustment.
Cooling System:
Potential for radiator leaks or thermostat issues over time; proper coolant maintenance is crucial.
Kawasaki Heritage:
Kawasaki Heavy Industries, Ltd. has a long history of producing robust and reliable motorcycles, often with an off-road or dual-sport focus.
Klr Lineage:
The KLR250 is a predecessor to the highly popular KLR650, establishing a reputation for versatility and dependability in the dual-sport segment.
Production Period:
The KLR250 model was produced from 1984 through 2005, with various iterative updates.
Manufacturing Location:
Japan
