This service repair manual covers the KLX250R, KLX250, and KLX300R models from the first generation, produced between 1993 and 1997. These dual-sport and enduro motorcycles are known for their off-road capability and versatility, building on a strong heritage in off-road racing. With a 4-stroke, liquid-cooled, DOHC, single-cylinder engine, available in 249cc and 292cc displacements, these bikes offered a balanced performance suitable for both trail riding and everyday use.
This comprehensive English-language manual provides factory-level detail essential for owners, mechanics, and technicians. It covers all major systems including the fuel, cooling, engine (top end, lubrication, right/left side assemblies, removal/installation), crankshaft, transmission, wheels, tires, final drive, brakes, suspension, steering, frame, and electrical system, complete with wiring diagrams. Procedures for maintenance, assembly, disassembly, troubleshooting, repair, component overhaul, and specification adjustments are thoroughly explained, ensuring the longevity and optimal performance of your KLX.
Model:
KLX250R/KLX250/KLX300R
Model Codes:
KLX250-D1, KLX250-D2, KLX250-D3, KLX250-D4, KLX250-E1, KLX250-E2, KLX250-E3, KLX250G-1, KLX300-A2
Generation:
First Generation (1993-1997)
Market Segment:
Dual-Sport / Enduro Motorcycle
Competitors:
Yamaha WR250Z, Honda CR250R (off-road variants), Suzuki DR-Z series
Target Audience:
Owners, mechanics, and enthusiasts of the Kawasaki KLX250R, KLX250, and KLX300R models from 1993-1997.
Value Proposition:
Provides essential factory-level diagnostic and repair information to maintain and restore these off-road capable motorcycles.
Coverage Areas:
General Information, Fuel System, Cooling System, Engine Top End, Engine Right Side/Left Side, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame, Electrical System, Appendix, 1994 Model Supplement, KLX300R Supplement
Manual Type:
Service Repair Manual
Systems Covered:
Engine (Top End, Lubrication, Right/Left Side Assemblies, Removal/Installation), Fuel System, Cooling System, Transmission, Crankshaft, Wheels, Tires, Final Drive, Braking System, Suspension (Front and Rear), Steering System, Frame, Electrical System (Wiring Diagrams Included)
Procedures Included:
Maintenance, Assembly, Disassembly, Troubleshooting, Repair, Component Overhaul, Wiring Diagram Interpretation, Spec Adjustments
Technical Depth:
Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics. Covers detailed procedures for complete engine rebuilds, suspension tuning, and electrical system diagnostics.
Print Quality:
High Quality PDF
Printable:
All pages are printable
Delivery Method:
Instant Download
Operating Systems:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Engine Type:
4-stroke, Liquid-cooled, DOHC, Single Cylinder
Displacement Klx250:
249 cc
Displacement Klx300:
292 cc
Bore X Stroke Klx250:
72.0 x 61.2 mm
Bore X Stroke Klx300:
78.0 x 61.2 mm
Compression Ratio Klx250:
10.0:1 (approx.)
Compression Ratio Klx300:
10.0:1 (approx.)
Fuel Delivery:
Carburetor (likely Keihin CV type)
Carburetor Size Klx250:
Likely 32-34mm
Carburetor Size Klx300:
Likely 34-35mm
Oil Type:
API SG, SAE 10W-40 or 20W-50 Motorcycle Specific
Oil Capacity With Filter:
Refer to manual for exact capacity (typically around 1.8-2.0L)
Transmission Type:
6-speed constant mesh
Gear Ratios:
Specific ratios available in manual
Clutch Type:
Wet, multi-disc
Clutch Fluid:
Refer to manual for specification (typically dedicated clutch fluid or brake fluid DOT 3/4 for hydraulic systems)
Dry Weight Klx250:
Approximately 118-125 kg (260-275 lbs) depending on trim/year
Dry Weight Klx300:
Approximately 125-130 kg (275-286 lbs)
Fuel Capacity:
Approximately 9.0 - 10.0 Liters (2.4 - 2.6 US gal)
Braking System:
Front: Disc, Rear: Disc
Brake Fluid:
DOT 3 or DOT 4
Tire Sizes:
Front: 3.00-21, Rear: 100/90-18 (typical, refer to manual for exact fitment)
Infotainment System:
N/A (Basic analog instrumentation)
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Change Interval:
Every 2,000-3,000 km (1,200-1,800 miles) or 6 months
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions
Spark Plug Replacement:
Refer to manual, typically every 5,000-10,000 km (3,000-6,000 miles)
Coolant Type:
Permanent type antifreeze (ethylene glycol based), 50/50 mix with distilled water
Fork Oil Type:
Refer to manual for viscosity (e.g., Showa SS-8 or equivalent 5W/10W)
Common Wear Items:
Clutch plates, valve guides, carburetor diaphragms, exhaust seals, wheel bearings.
Cooling System Considerations:
Regular coolant flushes and inspection of hoses and radiator fins are crucial for preventing overheating, especially under heavy use.
Kawasaki Offroad Legacy:
Kawasaki has a long-standing reputation in off-road and dual-sport motorcycles, with the KLX line evolving from earlier KX racing platforms.
Klx Line Introduction:
The KLX250R and KLX300R were developed as versatile off-road and dual-sport machines, offering a balance of performance and usability.
Production Period Covered:
1993, 1994, 1995, 1996, 1997
Offroad Magazine Reviews:
While specific awards are rare for service manuals themselves, the KLX series received positive reviews for its capability and reliability in off-road and dual-sport applications during its production years.