Segment:
Dual-sport motorcycle, known for off-road capability and street legality.
Competitors 1994:
Honda XR250L, Yamaha XT250, Suzuki DR250SE.
Design Philosophy:
Robust, trail-oriented design with practicality for everyday use.
Engine Type:
Air-cooled, four-stroke single-cylinder, emphasizing reliability and accessible power.
Suspension:
Long-travel suspension for off-road performance and comfortable ride quality.
Primary Focus:
Workshop Service and Repair
Scope:
Comprehensive maintenance, troubleshooting, repair, and overhaul procedures.
Type:
Factory Authorized Service Manual / Workshop Manual
Powertrain:
Engine, transmission, clutch, ignition system, cooling system.
Chassis:
Suspension (front forks, rear shock absorber), steering, brakes (front disc, rear drum), wheels, tires.
Electrical:
Lighting system, instrumentation, battery, charging system, starting system, wiring diagrams.
Bodywork:
Frame, body panels, fuel tank, seat, fenders, exhaust system.
Maintenance:
Routine maintenance checks, lubrication, oil changes, filter replacements, chain adjustment, spark plug replacement, brake pad replacement.
Repair:
Engine disassembly and reassembly, carburetor tuning and rebuilding, transmission overhaul, suspension fork service, brake system bleeding and caliper repair, electrical component testing and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding charts, symptom-based diagnostics.
Level:
Comprehensive from basic rider maintenance to full engine rebuilds and advanced diagnostics.
Crash Safety:
N/A (Motorcycle, not subjected to automotive crash tests)
Braking System:
Front: Disc, Rear: Drum
Lighting:
Headlight, taillight, brake lights, turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame.
Features:
Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, engine temperature warning light, neutral indicator, turn signal indicators.
Features:
None (characteristic of motorcycles from this era)
Oil Change Interval:
Every 3,000 km (1,800 mi) or 6 months
Air Filter Cleaning:
Every 1,000 km (600 mi) or 6 months
Spark Plug Replacement:
Every 6,000 km (3,600 mi) or 12 months
Chain Lubrication:
Every 500 km (300 mi) and after washing or riding in rain
Engine Oil Spec:
SAE 10W-40 API SG
Brake Fluid Spec:
DOT 3 or DOT 4
Carburetor Tuning:
Can be sensitive to altitude and require periodic re-tuning for optimal performance.
Suspension Seals:
Front fork seals may require replacement over time due to off-road use.
Carburetor Jetting:
Stock jetting might be lean for some environments, aftermarket rejetting can improve performance.
Common Filters:
Oil filter element, air filter element (specific part numbers available in manual).
Kawasaki Motorsports:
Kawasaki has a strong heritage in off-road and dual-sport motorcycles, dating back to early models like the Samurai.
Klx Lineage:
The KLX line has evolved from earlier models to offer versatile dual-sport capabilities. The 1994 E2 represents a refinement of the established KLX250 platform.
Production Period Klx250:
The KLX250 platform has been in continuous production in various forms since the 1970s, with significant updates over the decades.
Manufacture Location:
Japan
