Vehicle Category:
Dual-sport motorcycle, known for its versatility on and off-road.
Competitors:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z400S.
Target Audience:
Riders seeking a capable and reliable machine for commuting, trail riding, and light adventure touring.
Manual Value Proposition:
Essential resource for owners and technicians to maintain, diagnose, and repair the Kawasaki KLX250SA, ensuring optimal performance and longevity.
Engine:
Complete engine disassembly, assembly, inspection, and repair of all internal and external components, including cylinder head, piston, crankshaft, camshaft, valves, timing system, and cooling system.
Fuel System:
Carburetor system diagnosis, cleaning, adjustment, and overhaul; fuel tank, fuel pump, and fuel lines maintenance and replacement.
Ignition System:
CDI unit, ignition coil, spark plug, and wiring checks, testing, and replacement.
Transmission:
Clutch operation, disassembly, assembly, inspection, and adjustment; gearbox internal inspection, lubrication, and repair.
Drivetrain:
Chain and sprocket inspection, adjustment, and replacement; rear wheel hub and bearing service.
Suspension:
Front fork (telescopic) disassembly, inspection, seal replacement, oil level and type specifications; rear shock absorber inspection and service.
Brakes:
Front and rear brake system diagnosis, pad replacement, caliper overhaul, master cylinder service, brake fluid type and bleeding procedures.
Electrical System:
Wiring diagrams for all circuits, battery testing and maintenance, charging system (stator, regulator/rectifier) testing, lighting system, instrumentation, and starter motor troubleshooting.
Chassis And Bodywork:
Frame inspection, handlebar, seat, fuel tank, fenders, and side cover removal and installation procedures.
Wheels And Tires:
Tire pressure recommendations, wheel bearing inspection and lubrication, spoke tension adjustment.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacement, chain lubrication, brake adjustments, and general inspection procedures.
Troubleshooting:
Comprehensive diagnostic charts and flowcharts for identifying and resolving common issues across all vehicle systems.
Repair:
Detailed step-by-step instructions for disassembling, repairing, and reassembling all major components and sub-assemblies.
Specifications:
Torque specifications for all fasteners, engine tolerances, fluid capacities, electrical component specifications, and measurement data.
Special Tools:
Identification of any special tools required for specific repair or maintenance procedures.
Depth Level:
Comprehensive (from basic maintenance to complete engine rebuilds and complex electrical diagnostics).
Engine Type:
Four-stroke, DOHC, single-cylinder, liquid-cooled
Displacement:
249 cc (15.2 cu in)
Bore X Stroke:
72.0 x 61.1 mm (2.8 x 2.4 in)
Compression Ratio:
11.0:1
Horsepower:
Approximately 22 hp @ 7,500 rpm (varies by region and tuning)
Torque:
Approximately 15 lb-ft @ 6,000 rpm (varies by region and tuning)
Carburetor:
Keihin FCR32 (Flat CR - Constant Velocity Rectangular) with acceleration pump
Fuel Tank Capacity:
2.4 US gal (9.1 L)
Oil Type:
API SG or SH, SAE 10W-40, JASO MA certified motorcycle oil
Oil Capacity With Filter Change:
1.7 L (1.8 US qt)
Coolant Type:
Permanent type anti-freeze, 50% solution in distilled water (Kawasaki Coolant recommended)
Spark Plug Type:
NGK CR8E or equivalent
Spark Plug Gap:
0.7 - 0.8 mm (0.028 - 0.031 in)
Infotainment System:
N/A (Basic motorcycle instrumentation)
ABS:
Not equipped as standard on this model. Some later KLX models or variants may offer ABS.
Connectivity Features:
N/A
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights for neutral, turn signals, high beam, and engine warning.
Engine Oil Change:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first.
Oil Filter Replacement:
At every engine oil change.
Air Filter Cleaning:
Every 3,000 km (1,800 mi) or 6 months. Replace every 12,000 km (7,500 mi).
Spark Plug Inspection:
Every 6,000 km (3,700 mi). Replace as needed.
Chain Lubrication:
Every 1,000 km (600 mi) or after riding in rain/wet conditions.
Chain Tension Adjustment:
Every 1,000 km (600 mi).
Brake Fluid Replacement:
Every 2 years or as needed based on condition.
Coolant Replacement:
Every 2 years or 24,000 km (15,000 mi).
Engine Oil Spec:
API SG or SH, SAE 10W-40, JASO MA
Brake Fluid Spec:
DOT 3 or DOT 4
Coolant Spec:
50% solution of permanent type anti-freeze in distilled water
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, wheel bearings, and brake pads are common wear items that may require periodic replacement.
Carburetor Tuning:
Carburetor can be sensitive to altitude and temperature changes, requiring periodic adjustment for optimal performance.
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries Motorcycle & Engine division has a long and storied history in motorcycle manufacturing, known for performance and innovation across various categories.
Klx Lineage:
The KLX series represents Kawasaki's commitment to off-road and dual-sport motorcycles, evolving over decades to incorporate technological advancements and user feedback.
Manufacturing Location:
Primarily Japan (specific assembly locations may vary by market).
