Market Segment:
Dual-sport motorcycle, targeted at off-road capability with street legality.
Competitors:
Honda XR250L, Yamaha XT225, Suzuki DR250S.
Unique Selling Points:
Compact and lightweight design, robust off-road performance for its class, reliable single-cylinder engine.
Target Audience:
Riders seeking an entry-level to intermediate dual-sport for trail riding, commuting, and light adventure touring.
Engine:
Complete overhaul, disassembly, inspection, assembly, tuning, carburetion, ignition, cooling, lubrication.
Transmission:
Clutch, gearbox, shift mechanism, lubrication, disassembly and assembly.
Chassis:
Frame, swingarm, linkage, bearings, suspension (forks and rear shock), steering system.
Brakes:
Hydraulic front and rear brake systems, caliper service, master cylinder, brake lines, bleeding procedures.
Electrical:
Wiring diagrams, lighting system, ignition system, charging system (stator, regulator/rectifier), battery, starter motor, troubleshooting.
Fuel System:
Carburetor (Kawasaki VM26SS) disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel filter.
Exhaust System:
Exhaust pipe, muffler, mounting, inspection.
Wheels And Tires:
Spoke wheel service, tire removal/installation, wheel balancing, rim specifications.
Bodywork:
Fairing, fenders, seat, fuel tank cover, decals, removal and installation.
Maintenance:
Scheduled maintenance checks, lubrication points, chain adjustment, brake adjustments, oil changes.
Troubleshooting:
Diagnostic charts for common performance issues, electrical problems, starting difficulties.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly for all major systems.
Tune Up:
Carburetor tuning, spark plug replacement, ignition timing adjustment, valve clearance adjustment.
Special Tools:
Identification and usage of specialized tools required for specific procedures.
Depth:
Comprehensive coverage suitable for both intermediate home mechanics and professional technicians. Includes detailed specifications, torque values, tolerances, and diagnostic procedures.
Searchability:
Fully searchable text for quick information retrieval.
Printability:
Printable pages for on-hand reference.
Resolution:
High-resolution scans ensuring clarity of diagrams and text.
Binding:
Not applicable (digital format), but original factory manuals typically had saddle-stitch or perfect binding.
Paper:
Not applicable (digital format), but original factory manuals were printed on durable, matte-finish paper.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4 valves.
Displacement:
249 cc (15.2 cu in)
Bore X Stroke:
72.0 x 61.1 mm (2.83 x 2.41 in)
Cooling System:
Liquid-cooled
Compression Ratio:
11.0:1
Horsepower Est:
~28 HP @ 7500 RPM (Estimate based on typical outputs for the era and engine)
Torque Est:
~19 lb-ft @ 6000 RPM (Estimate based on typical outputs for the era and engine)
Carburetor:
Kawasaki VM26SS, single
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
10.0 L (2.6 US gal)
Safety Ratings:
Not applicable in the same way as automobiles; focus is on rider safety features and design integrity.
Braking System:
Hydraulic disc front and rear.
Lighting:
Halogen headlight, taillight, and turn signals for visibility.
Frame Construction:
Steel frame designed for durability and off-road stress.
Tires:
Dual-purpose tread pattern for grip on varied surfaces.
Infotainment System:
Basic analog instrument cluster: speedometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators.
Driver Assistance Systems:
None (typical for motorcycles of this era).
Connectivity Features:
None (typical for motorcycles of this era).
Oil Change Interval:
Every 2,000 km (1,200 miles) or 6 months.
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions.
Spark Plug Check:
Every 2,000 km (1,200 miles).
Valve Clearance Check:
Every 4,000 km (2,400 miles).
Chain Lubrication:
Every 500 km (300 miles) or after washing/rain.
Engine Oil Type:
SAE 10W-40 API SE or SF, JASO MA.
Engine Oil Capacity:
1.6 L (1.7 US qt) without filter change; 1.8 L (1.9 US qt) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio).
Brake Fluid Type:
DOT 3 or DOT 4.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment. VM26SS can be finicky.
Clutch Wear:
Clutch plates can wear over time, especially with aggressive off-road use, leading to slipping.
Suspension Seals:
Fork seals and rear shock seals can degrade with age and mileage, leading to leaks.
Electrical Connections:
Corrosion in electrical connectors can occur, especially if regularly exposed to moisture, affecting lights or ignition.
Cam Chain Tensioner:
Some KLX models are known to have automatic cam chain tensioners that can fail or become noisy over time, requiring replacement.
Manufacturer History:
Kawasaki Heavy Industries is a Japanese corporation known for its motorcycles, engines, and heavy equipment. It has a long history of innovation in performance and engineering.
Klx Series Introduction:
The KLX series represents Kawasaki's line of dual-sport and off-road motorcycles, emphasizing versatility and off-road capability.
Klx250 Development:
The KLX250 evolved from earlier dual-sport models, offering a balance of performance and manageable weight for both on-road and off-road use.
Production Period Estimate:
The KLX250 was produced in various iterations from the late 1970s through the 2000s, with the 1994 E2 model being a significant iteration of the air-cooled generation before the introduction of the fuel-injected model.
Manufacturing Location:
Japan
Awards And Recognitions:
While specific awards for the 1994 KLX250 are not prominently documented, the KLX lineage has consistently been praised for its off-road prowess and durability in its class by motorcycle publications.
Owner Satisfaction General:
Generally positive among owners who appreciate its ruggedness and dual-sport capability, though often noted as an older design.
Emission Standards:
Designed to meet prevailing emission standards for motorcycles in its production year and market.
