Segment:
Dual-sport and off-road motorcycles, popular for trail riding and light street use.
Target Audience:
Owners and mechanics seeking to maintain, repair, or restore Kawasaki KLX250/KLX250R models from the mid-1990s.
Competitors At Time:
Honda XR series, Yamaha WR/XT series, Suzuki DR series.
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder engine.
Suspension Type:
Long-travel suspension, typically inverted front forks and a monoshock rear suspension.
Intended Use:
Versatile, capable on trails, dirt roads, and for light commuting.
Primary Coverage:
Comprehensive repair, service, and maintenance
Specific Models Covered:
KLX250 (standard model) and KLX250R (racing/off-road model)
Estimated Page Count:
Approximately 400-500 pages (typical for comprehensive service manuals)
Type:
Factory Authorized Repair Service Manual
Format:
Likely a digital format, such as PDF (common for aftermarket and digital distribution), but may also be available as a printed book.
Engine:
Detailed engine overhaul, including top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), and auxiliary systems (cooling, lubrication).
Transmission:
Complete transmission disassembly, inspection, repair, and assembly for both the gearbox and clutch mechanisms.
Fuel System:
Carburetor (likely Keihin CVK) tuning, cleaning, rebuilding, and fuel delivery system components (fuel tank, petcock, fuel lines).
Electrical System:
Wiring diagrams, ignition system components (CDI, coil, spark plug), lighting system, charging system (stator, regulator/rectifier), battery maintenance, and troubleshooting.
Suspension:
Front fork (telescopic, inverted) overhaul, seal replacement, oil changes, and rear shock absorber service and adjustment.
Brakes:
Front and rear brake system maintenance, including caliper overhaul, master cylinder service, pad replacement, fluid bleeding, and rotor inspection.
Cooling System:
Radiator service, fan operation, coolant types and capacities, and troubleshooting of overheating issues.
Exhaust System:
Inspection and maintenance of the exhaust manifold, muffler, and related components.
Frame And Bodywork:
Chassis components, body panel removal and installation, seat, fenders, and general frame integrity checks.
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, chain adjustment, and general inspection.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, often presented in a symptom-based format.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Rebuilds:
Complete engine and transmission rebuild procedures, including torque specifications and clearances.
Wiring Diagrams:
Detailed electrical schematics for easy diagnosis and repair of electrical faults.
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine and transmission overhauls, suitable for professional mechanics and experienced DIY enthusiasts.
Format Type:
PDF (if digital) or Printed Book
Searchability:
Likely searchable text if a PDF document, allowing for quick information retrieval.
Quality:
Typically high-quality, with clear diagrams and readable text, especially for factory-issued or reputable aftermarket manuals.
Binding:
Spiral-bound or perfect-bound for printed versions, facilitating lay-flat use in a workshop environment.
Paper:
Durable, possibly glossy paper to withstand workshop conditions for printed versions.
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder
Displacement:
249 cc (approximately)
Bore X Stroke:
Typically around 72.0 mm x 61.2 mm (check specific model year documentation for exact figures).
Compression Ratio:
Around 10.0:1 to 11.0:1 (subject to variation by year and specific market).
Horsepower:
Approximately 28-32 hp (at the crankshaft, subject to tuning and emission controls).
Torque:
Approximately 18-20 lb-ft (at the crankshaft).
Carburetor Type:
Keihin CVK (Constant Velocity Carburetor), likely a single 34mm or 36mm unit.
Fuel Type:
Unleaded gasoline (Octane rating as specified in manual, typically 87 AKI or higher).
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Oil Type:
Typically JASO MA certified motorcycle-specific 4-stroke engine oil (e.g., 10W-40 or 20W-50, consult manual for precise viscosity and API classification).
Cooling Medium:
Ethylene glycol-based coolant mixed with distilled water (50/50 ratio typically).
Transmission Type:
Constant mesh, 6-speed manual transmission
Clutch Type:
Wet, multi-disc manual clutch
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning and diagnostics.
Transmission Fluid Type:
Motorcycle transmission/clutch specific oil, often the same as the engine oil if it meets JASO MA specifications, or dedicated gear oil. Manual is definitive.
Length:
Approx. 2180 mm (85.8 in) for KLX250, KLX250R may vary slightly.
Width:
Approx. 810 mm (31.9 in) at handlebars.
Height:
Approx. 1205 mm (47.4 in) to seat.
Wheelbase:
Approx. 1430 mm (56.3 in).
Dry Weight:
Approx. 110-115 kg (242.5-253.5 lbs) for KLX250, KLX250R may be slightly lighter.
Curb Weight:
Not always specified, but typically around 125-130 kg with fluids.
Cargo Capacity:
N/A (motorcycle)
Crash Test Ratings:
N/A (motorcycles are not subjected to automotive crash test ratings).
Braking System:
Disc brakes front and rear, providing effective stopping power.
Lighting:
Headlight, taillight, brake light, turn signals (may be optional/removable on KLX250R).
Frame Construction:
High-tensile steel perimeter frame for rigidity and durability.
Oil Change Interval:
Typically every 3,000-4,000 km (1,800-2,500 miles) or annually, whichever comes first. Consult manual for exact recommendation and oil type.
Air Filter Cleaning:
Regular cleaning (every few hundred miles or as needed based on conditions), replacement as per manual's schedule.
Spark Plug Replacement:
Typically around 6,000-10,000 km (3,700-6,200 miles), but check gap and condition more frequently.
Chain Maintenance:
Lubrication and adjustment every 500-1,000 km (300-600 miles) and inspection for wear.
Engine Oil Capacity:
Approx. 1.4 - 1.6 liters (with filter change), exact amount specified in manual.
Coolant Capacity:
Approx. 0.8 - 1.0 liters, consult manual for exact capacity and type.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific recommendation).
Carburetor Performance:
Carburetor can be prone to clogging if fuel is not clean or if left to sit for extended periods. Tuning for altitude or modifications is common.
Suspension Seals:
Fork seals can wear over time, leading to leaks. Regular maintenance and cleaning are recommended.
Cam Chain Tensioner:
While not as common as on some other models, the cam chain tensioner can eventually require adjustment or replacement. A rattling noise could indicate this.
Exhaust Flange Gasket:
The exhaust header flange gasket can sometimes fail, leading to exhaust leaks at the cylinder head.
Kawasaki Offroad Legacy:
Kawasaki has a long and successful history in off-road and motocross racing, with models like the KX series and earlier KLX iterations paving the way.
Klx250 Lineage:
The KLX250 line evolved from earlier Kawasaki dual-sport offerings, aiming to provide a versatile and capable machine for both trail and light street use. The 'R' designation typically signified a more performance-oriented, off-road-focused version.
Manufacturing Period:
The 1993-1997 models represent a specific generation of the KLX250, with subsequent generations featuring updates and variations.
Manufacturing Location:
Primarily Japan.
