Vehicle Type:
Dual-sport / Enduro motorcycle, designed for both on-road and off-road use.
Competitors Era:
Competed with other Japanese manufacturers' dual-sport offerings like Yamaha XT series, Suzuki DR series, and Honda XR/XL series in its displacement class.
Design Philosophy:
Robust and reliable single-cylinder engine, capable suspension, durable construction for adventure and everyday riding.
Manual Value Proposition:
Provides essential technical information for owners and mechanics to maintain, repair, and troubleshoot the Kawasaki KLX250 models from 1993-1997.
Engine:
Complete overhaul, inspection, tuning, carburetor, lubrication system, cooling system (liquid-cooled on some variants), ignition system.
Transmission:
Clutch, gearbox, shift mechanism, internal components, lubrication, troubleshooting.
Chassis:
Frame, suspension (front fork, rear shock absorber), swingarm, steering system, wheel bearings, spokes.
Brakes:
Front and rear brake systems (disc brakes), caliper maintenance, brake fluid, bleeding procedures, master cylinder.
Electrical:
Wiring diagrams, lighting system, battery, charging system (stator, regulator/rectifier), starter motor, ignition coil, fuses, switches.
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor (specific model identification may be needed), operation and tuning.
Exhaust:
Exhaust pipe, muffler, mounting, inspection for leaks and damage.
Bodywork:
Fairings, fenders, seat, fuel tank, graphics, mounting points, removal and installation.
Maintenance:
Regular service intervals, oil changes, filter replacements, chain adjustment, spark plug replacement, brake pad inspection/replacement, coolant checks (if applicable).
Troubleshooting:
Diagnostic flowcharts and procedures for common problems related to starting, running, electrical issues, and performance.
Repair:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly for all major systems.
Engine Rebuild:
Full engine disassembly, piston, ring, cylinder, valve, and gasket replacement procedures. Torque specifications for critical fasteners.
Suspension Service:
Front fork oil change, seal replacement, rear shock absorber inspection and adjustment.
Carburetor Tuning:
Adjustment of idle speed, jetting recommendations, cleaning and rebuilding procedures.
Depth Level:
Comprehensive (covers routine maintenance to complete engine rebuilds and electrical diagnostics).
Diagnostic Capability:
Detailed diagnostic information, including fault codes (if applicable for the era) and symptom-based troubleshooting guides.
Schematics:
Includes detailed wiring diagrams and service schematics for all major systems.
Engine Type:
Four-stroke, DOHC, 4-valve, Liquid-cooled, Single-cylinder.
Displacement:
249 cc (actual displacement may vary slightly by market variant).
Bore X Stroke:
Typically around 72.0 mm x 61.2 mm (verify for specific sub-models).
Compression Ratio:
Around 10.0:1 to 11.0:1 (verify for specific sub-models).
Horsepower:
Approximately 26-30 HP @ 8,000 RPM (varies by market emissions regulations and tuning).
Torque:
Approximately 22-24 Nm @ 6,500 RPM (varies by market emissions regulations and tuning).
Carburetor:
Single Keihin CVK (Constant Velocity Carburetor) - specific model numbers like CVK34 or CVK36 common. Manual will detail proper jetting and adjustment.
Fuel Capacity:
Approximately 10-12 liters (2.6-3.2 US gallons) depending on model variant.
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with electronic advance.
Oil Capacity With Filter:
Approximately 1.5 - 1.8 liters (1.6 - 1.9 US quarts) - refer to manual for exact amount and checking procedure.
Oil Type Recommendation:
API SG or higher, SAE 10W-40 motorcycle specific oil is generally recommended. Manual will provide precise specifications.
Transmission Type:
6-speed constant mesh, return type.
Clutch Type:
Wet, multi-disc, cable-actuated.
Final Drive:
Chain drive. Manual covers chain inspection, lubrication, adjustment, and replacement.
Transmission Oil Type:
Manual will specify appropriate gearbox oil or engine oil viscosity for the transmission. Often uses the same oil as the engine.
Overall Length:
Approximately 2170 mm (85.4 in).
Overall Width:
Approximately 805 mm (31.7 in).
Overall Height:
Approximately 1175 mm (46.3 in).
Wheelbase:
Approximately 1430 mm (56.3 in).
Ground Clearance:
Approximately 270 mm (10.6 in).
Dry Weight:
Approximately 120-125 kg (265-275 lbs).
Curb Weight:
Approximately 130-135 kg (287-298 lbs) with all fluids.
Front Tire Size:
80/100-21 M/C 51P (tube type).
Rear Tire Size:
100/90-18 M/C 56P (tube type).
Wheel Type:
Spoked wheels with aluminum or steel rims.
Front Suspension Travel:
Approximately 275 mm (10.8 in) for the telescopic fork.
Rear Suspension Travel:
Approximately 260 mm (10.2 in) for the Uni-Trak system.
Crash Test Ratings:
N/A (Motorcycles typically do not have standardized crash test ratings like cars).
Braking System:
Hydraulic disc brakes front and rear. Manual details inspection and maintenance procedures.
Lighting:
Headlight, taillight, brake light, turn signals. Manual covers bulb replacement and electrical troubleshooting.
Frame Construction:
High-tensile steel semi-double cradle frame, providing stability and durability.
Oil Change Interval:
Typically every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first. Manual will have the definitive schedule.
Air Filter Cleaning:
Recommended every 1,000-2,000 km (600-1,200 miles), with replacement as needed. Manual will detail cleaning/replacement procedures.
Spark Plug Replacement:
Typically every 5,000-10,000 km (3,000-6,000 miles), depending on spark plug type and condition. Manual will specify type and gap.
Chain Maintenance:
Lubricate and adjust chain every 500-1,000 km (300-600 miles), or after riding in wet/dirty conditions.
Coolant Type:
If liquid-cooled, typically a 50/50 mix of ethylene glycol-based antifreeze and distilled water. Manual will specify type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify the exact requirement.
Common Wear Items:
Chain and sprockets, brake pads, tires, fork seals (due to off-road use), clutch plates.
Carburetor Issues:
Can be susceptible to gumming up if fuel sits for extended periods, requiring cleaning and potentially jetting adjustments.
Electrical Gremlins:
Older bikes can experience issues with aging wiring, connectors, and components like the regulator/rectifier. Manual is crucial for diagnostics.
Kawasaki Legacy:
Kawasaki has a long history in motorcycle manufacturing, known for performance and durability in various categories, including off-road and dual-sport.
Klx Lineage:
The KLX line has been a staple for Kawasaki in the dual-sport segment, evolving from earlier models to incorporate modern technology and design.
Manufacturing Location:
Likely manufactured in Japan, though regional assembly plants could exist for different markets.
Sales Performance:
The KLX250 was a popular model for its versatility, catering to riders seeking a capable machine for commuting and light off-road adventures.
