🏷️ Basic Information

Make:

Kawasaki

Model:

KLX250 / D-Tracker / KLX250R

Model Aliases:

KLX250SR (Japan market variant)

Model Years Covered:

1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Engine Codes:

KL250-G (example - actual specific codes may vary by sub-model and market)

👋 Introduction

Category:

Dual-sport / Supermoto Motorcycle

Target Audience:

Off-road enthusiasts, commuters, Supermoto riders.

Competitors Historical:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250, KTM 250 EXC.

Versatility:

Adaptable for both off-road trails and street riding (especially D-Tracker variant).

Reliability:

Known for robust Kawasaki engineering and durability.

Performance:

Adequate power for its class, agile handling.

📋 Manual Details

Coverage Scope:

Complete Workshop Service and Repair

All Models Included:

True

All Engines Included:

True

All Trim Levels Included:

True

All Transmission Types Included:

True

Estimated Page Count:

High (Typically 400+ pages for a comprehensive service manual covering this many years)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, overhaul, cylinder head, cylinder block, crankshaft, pistons, connecting rods, valve train, timing system.

Fuel System:

Carburetor(s) disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel tank maintenance.

Ignition System:

Ignition timing, spark plugs, ignition coils, CDI unit, wiring.

Cooling System:

Radiator, coolant, hoses, thermostat, water pump.

Exhaust System:

Exhaust pipes, muffler, mounting.

Transmission:

Clutch operation, gearbox disassembly, assembly, gear shift mechanism, lubrication.

Drivetrain:

Chain drive system (sprockets, chain inspection, adjustment, replacement).

Suspension Front:

Front fork disassembly, assembly, oil change, seal replacement, springs.

Suspension Rear:

Rear shock absorber, linkage system, swingarm maintenance.

Brakes Front:

Brake caliper, master cylinder, brake lines, brake pads, brake disc inspection and replacement.

Brakes Rear:

Brake drum or disc (depending on specific D-Tracker/KLX250R variant), brake shoes, brake lever/pedal adjustment.

Wheels And Tires:

Wheel bearing maintenance, spoke tension, tire inspection and replacement, rim specifications.

Electrical System:

Wiring diagrams, battery maintenance, lighting system, charging system (stator, regulator/rectifier), starter motor, horn.

Frame And Bodywork:

Frame inspection, handlebars, fuel tank removal/installation, seat, fenders, plastics.

Controls:

Throttle controls, clutch lever, brake lever, footpegs, shifter adjustment.

Instruments And Gauges:

Speedometer, tachometer, indicator lights, troubleshooting.

Routine Maintenance:

Oil changes, filter replacement, chain lubrication and adjustment, air filter cleaning/replacement, spark plug inspection, brake checks.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, fault finding charts.

Major Repairs:

Engine rebuilds, transmission overhaul, suspension component replacement, carburetor rebuilding.

Component Overhaul:

Detailed steps for dismantling, cleaning, inspecting, and reassembling key components.

Torque Specifications:

Precise torque values for all critical fasteners.

Wiring Diagrams:

Comprehensive electrical system schematics for easy diagnosis and repair.

Special Tool Identification:

Identification of necessary special tools required for specific procedures.

Depth:

Comprehensive (From basic rider maintenance to full engine and chassis rebuilds)

Diagnostic Capability:

Advanced diagnostic procedures and troubleshooting guides.

Illustrations:

Step-by-step illustrations and diagrams for clarity.

📊 Manual Specifications

Format:

PDF

Compatibility:

PC, MAC, Tablets, Smartphones

Required Software:

Adobe Reader (Free Download)

Quality:

High Quality (Printable)

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Type:

Four-stroke, DOHC, Single-cylinder

Displacement:

249 cc (249 cubic centimeters)

Bore X Stroke:

72.0 x 61.2 mm

Cooling System:

Liquid-cooled

Horsepower Estimated:

Approximately 25-30 HP (Varies by market and specific model year tune)

Torque Estimated:

Approximately 20-23 Nm (Varies by market and specific model year tune)

Fuel Delivery:

Carburetor (e.g., Keihin CVK34 or similar for most models in this range)

Fuel Type:

Unleaded Gasoline

Ignition:

Digital CDI with electronic advance

Starter:

Electric Start (standard on most models, kick start backup may be present on some early models)

🔧 Transmission

Type:

6-speed constant mesh

Optional Transmissions:

N/A (Manual transmission only for this model line)

Clutch:

Wet, multi-disc, manual operation

Final Drive:

Chain Drive

📐 Dimensions

Length Overall:

Approx. 2,165 mm (85.2 in) for KLX250R, may vary slightly for D-Tracker.

Width Overall:

Approx. 800 mm (31.5 in) for KLX250R, may vary slightly for D-Tracker.

Height Overall:

Approx. 1,190 mm (46.9 in) for KLX250R, may vary slightly for D-Tracker.

Wheelbase:

Approx. 1,430 mm (56.3 in)

Dry Weight:

Approx. 127 kg (280 lbs) for KLX250R, may vary slightly for D-Tracker.

Curb Weight:

Approx. 136 kg (300 lbs) for KLX250R (with all fluids and ready to ride), may vary.

Fuel Capacity:

Approx. 10 Liters (2.6 US gal)

🛡️ Safety Features

Safety Standards:

Meets applicable national/international safety and emissions standards for its class and era.

Brakes:

Disc brakes front and rear (specific configurations may vary slightly, D-Tracker typically has dual front discs on later models).

Lighting:

Headlight, taillight, brake lights, turn signals.

Frame Design:

Perimeter frame for rigidity and stability.

Ergonomics:

Designed for rider control and comfort in varied riding conditions.

💡 Technology Features

Infotainment System:

N/A (Basic instrumentation only)

Advanced Features:

N/A (Focus on mechanical and electrical systems)

🔧 Maintenance

Engine Oil Change:

Every 3,000-4,000 km (1,800-2,500 miles) or 6 months, whichever comes first (refer to manual for precise intervals).

Oil Filter Replacement:

At every engine oil change.

Air Filter Cleaning:

Every 1,000-2,000 km (600-1,200 miles) or more frequently in dusty conditions.

Spark Plug Inspection:

Every 3,000-4,000 km (1,800-2,500 miles).

Chain Lubrication Adjustment:

Every 500-1,000 km (300-600 miles) and before long rides.

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA compliant motorcycle oil.

Engine Oil Capacity:

Approx. 1.7 - 1.9 Liters (with filter change), check manual for exact spec.

Fork Oil Type:

SAE 5W or 10W suspension fluid (specific viscosity recommended by Kawasaki).

Coolant Type:

Permanent type ethylene glycol based coolant, diluted with distilled water (50/50 mix).

Common Wear Items:

Chain and sprockets, brake pads, tires, fork seals due to off-road use.

Carburetor Tuning:

May require periodic cleaning and adjustment, especially if modifications are made or fuel quality varies.

Electrical Connections:

Corrosion on connectors can occur with exposure to elements; inspect and clean periodically.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki has a long-standing reputation for robust and high-performing off-road and dual-sport motorcycles.

Klx Lineage:

The KLX line has evolved significantly, with the KLX250 platform being a popular choice for its blend of performance and affordability for decades. This generation (1993-2007) represents a key period of development.

D Tracker Origin:

The D-Tracker variant specifically targets the Supermoto segment with smaller wheels, street tires, and often upgraded suspension components.

Manufacturing Location Typical:

Japan

🏆 Awards & Recognition

Industry Acclaim:

Consistently recognized as a capable and reliable dual-sport/supermoto platform within its category during its production run.