Segment:
Dual-sport motorcycle, popular for off-road capability with street legality.
Competitors 1994:
Honda XR250L, Yamaha XT250, Suzuki DR250SE.
Klx250D2 Features:
Liquid-cooled, four-stroke engine; Kawasaki's Uni-Trak rear suspension; capable off-road chassis.
Primary Coverage:
Complete repair and service information for the 1994 Kawasaki KLX250-D2.
Secondary Coverage:
Maintenance schedules, troubleshooting guides, diagnostic procedures, specifications, and wiring diagrams.
Estimated Pages:
Approximately 300-400 pages (typical for this era and model type).
Type:
Workshop Service Manual / Repair Manual
Format:
Likely printed or a high-quality digital PDF reproduction.
Engine:
Top end, bottom end, cylinder head, piston, crankshaft, connecting rod, valve train, cooling system.
Fuel System:
Carburetor (Mikuni VM28), fuel pump, fuel lines, fuel tank.
Ignition System:
CDI, spark plug, ignition coil, timing.
Transmission:
Clutch, gearbox, shift mechanism, transmission oil.
Chassis:
Frame, front suspension (telescopic forks), rear suspension (monoshock, Uni-Trak system), swingarm.
Brakes:
Front disc brake, rear drum brake, brake fluid specifications, caliper service, master cylinder.
Electrical System:
Wiring diagrams, lighting, battery, charging system, starter motor, fuses, switches.
Wheels And Tires:
Spoke wheels, tire sizes, pressure, bearing maintenance.
Bodywork:
Fairings, fenders, seat, fuel tank, decals.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication, spark plug checks.
Troubleshooting:
Diagnostic flowcharts for common starting, running, and electrical issues.
Disassembly And Assembly:
Step-by-step instructions for major component removal and installation.
Rebuilding:
Detailed procedures for engine, carburetor, and brake system rebuilds.
Adjustments:
Carburetor synchronization, ignition timing, clutch and brake lever adjustments.
Special Tools:
Identification of and usage for specialized tools required for specific procedures.
Depth:
Comprehensive; covers everything from basic rider maintenance to full engine rebuilds and electrical diagnostics.
Digital Format Quality:
If digital, expect high-resolution scans of original pages, potentially searchable PDF.
Print Quality:
Professional printing, clear diagrams, legible text.
Binding:
Likely coil-bound or perfect-bound for ease of use in a workshop environment.
Paper Type:
Durable paper stock, often glossy or semi-gloss for clarity of diagrams.
Engine Type:
4-stroke, Liquid-cooled, DOHC, 4-valve
Displacement:
249 cc (249 cm³)
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Horsepower:
Approximately 20-25 HP (at crankshaft, estimated for model year).
Torque:
Approximately 18-20 Nm (at crankshaft, estimated for model year).
Carburetor Type:
Mikuni VM28SS (single carburetor)
Fuel Capacity:
Approximately 10.5 liters (2.8 US gal)
Oil Type:
SAE 10W-40 API SG or higher
Oil Capacity:
Approximately 1.6 liters (with filter change)
Length:
Approximately 2180 mm
Width:
Approximately 830 mm
Height:
Approximately 1170 mm
Wheelbase:
Approximately 1430 mm
Ground Clearance:
Approximately 265 mm
Dry Weight:
Approximately 120 kg (curb weight will be higher)
Curb Weight:
Approximately 133 kg (with fluids)
Gross Vehicle Weight Rating:
Not explicitly stated, but typically around 280-300 kg for this class.
Safety Ratings:
Motorcycles of this era do not have formal crash test ratings like cars. Safety relies on rider skill and bike design.
Braking System:
Front hydraulic disc, Rear drum brake.
Lighting:
Headlight, taillight, brake light, turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame for stability.
Suspension:
Long-travel suspension for absorbing impacts and maintaining control.
Engine Oil Change:
Every 3,000 km or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1,000 km or as needed based on operating conditions.
Spark Plug Inspection:
Every 3,000 km, replace as needed.
Chain Lubrication Adjustment:
Every 500 km, or more frequently in dusty/wet conditions.
Coolant Type:
Ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals.
Carburetor Tuning:
Can be sensitive to altitude and air filter condition; requires proper tuning for optimal performance.
Carburetor Idle Issues:
Pilot jet can sometimes become clogged leading to rough idle.
Fork Seals:
Can wear over time, leading to oil leaks, especially with off-road use.
Kawasaki Motorcycles:
Kawasaki has a long-standing reputation for performance and innovation in motorcycle manufacturing, particularly in off-road and dual-sport segments.
Klx Lineage:
The KLX series has evolved significantly, but the core ethos of a capable dual-sport machine has remained consistent. The 1994 model represents a refinement of earlier KLX designs.
Kawasaki Production Era:
The KLX250 model line has been in continuous production in various forms for decades, with significant updates occurring throughout its lifecycle.
Motorcycle Awards:
Specific awards for the 1994 KLX250-D2 are not widely documented in general automotive press, but the model was generally well-regarded for its class.
Consumer Reviews:
Owner reviews from the period often praised its reliability, off-road capability, and comfortable riding position for its intended use.
Emissions Certifications:
Met prevailing emissions standards for its respective market at the time of manufacture.
