🏷️ Basic Information

Make:

Kawasaki

Model:

KLX250

Applicable Years:

1993, 1994, 1995, 1996, 1997

Generation Identifier:

First Generation (KLX250)

Chassis Codes:

KLX250-D1, KLX250-D2, KLX250-D3, KLX250-D4, KLX250-D5

👋 Introduction

Segment:

Dual-Sport / Enduro Motorcycle

Target Audience:

Enthusiasts, off-road riders, daily commuters seeking versatility

Competitors:

Honda XR250, Yamaha WR250, Suzuki DR250

Features:

Lightweight chassis, capable off-road suspension, reliable engine, street-legal for versatility

📋 Manual Details

Geographic Coverage:

Global (specific regional variations may exist not detailed)

Total Pages:

299

Type:

Workshop Service Manual

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, top-end, bottom-end, valve timing, piston assembly, crankshaft, connecting rod, cylinder head, cylinder block

Fuel System:

Carburetor disassembly, adjustment, cleaning, fuel pump, fuel lines, fuel tank

Ignition System:

CDI unit, ignition coils, spark plugs, timing

Cooling System:

Radiator, coolant hoses, water pump, thermostat

Transmission:

Gearbox disassembly, inspection, lubrication, shift mechanism

Clutch:

Clutch plate inspection, operation, adjustments

Suspension Front:

Fork disassembly, seal replacement, oil levels, spring rates, adjustments

Suspension Rear:

Monoshock absorber, linkage system, swingarm, bearing maintenance

Brakes Front:

Caliper overhaul, piston seals, brake pads, brake disc inspection, fluid replacement

Brakes Rear:

Caliper overhaul, brake pads, brake disc inspection, fluid replacement

Electrical System:

Wiring diagrams, lighting, battery, charging system, starter motor, fuses

Frame And Bodywork:

Frame inspection, fairings, seat, handlebars, footpegs

Wheels And Tires:

Wheel bearing maintenance, spoke tension, tire pressure, tire inspection

Maintenance Schedule:

Detailed preventative maintenance intervals for all major components

Troubleshooting:

Comprehensive diagnostic procedures for common and uncommon issues

Disassembly And Assembly:

Step-by-step instructions for all major component overhauls and replacements

Torque Specifications:

Precise torque values for critical fasteners throughout the motorcycle

Adjustments:

Carburetor idle, clutch lever, brake levers, chain tension, suspension settings

Special Tools:

Identification of specific tools required for certain procedures

Depth Of Coverage:

Comprehensive, covering everything from basic servicing to complete engine and transmission rebuilds

Diagnostic Capability:

Advanced diagnostic charts and troubleshooting guides for electrical and mechanical faults

Rebuild Instructions:

Detailed instructions for rebuilding major components like the engine, transmission, and suspension

📊 Manual Specifications

Format:

PDF

Searchability:

Likely text-searchable, common for professional PDF manuals

Print Readability:

Designed for clarity, suitable for printing specific sections

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Manual Scope:

Full workshop manual covering all aspects of maintenance, repair, and troubleshooting.

⚙️ Engine Specifications

Engine Type:

Four-stroke, DOHC, single-cylinder, liquid-cooled

Displacement:

249 cc (approx.)

Bore X Stroke:

72.0 x 61.2 mm (typical for this generation)

Compression Ratio:

11.0:1 (typical)

Horsepower:

Approx. 25-30 HP (Varies by market and specific tuning)

Torque:

Approx. 20-23 Nm (Varies by market and specific tuning)

Carburetion:

Mikuni VM26SS (typical for this generation), possibly TM series on later models

Fuel Type:

Unleaded gasoline

Oil Capacity:

Approx. 1.5 - 2.0 liters (including filter), refer to manual for exact spec

Oil Type:

SAE 10W-40 or 20W-50 motorcycle specific, API SG or higher (refer to manual for exact spec)

🔧 Transmission

Type:

6-speed constant mesh

Optional Types:

N/A

Clutch Type:

Wet, multi-disc

Final Drive:

Chain drive

📐 Dimensions

Length:

Approx. 2,180 mm (Varies slightly by model year)

Width:

Approx. 810 mm (Varies slightly by model year)

Height:

Approx. 1,205 mm (Varies slightly by model year)

Wheelbase:

Approx. 1,430 mm (Varies slightly by model year)

Dry Weight:

Approx. 119 kg (Varies slightly by model year)

Wet Weight:

Approx. 132 kg (with fluids and full tank)

Fuel Capacity:

Approx. 10 liters (including reserve)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles typically do not have standardized crash test ratings like cars)

Braking System:

Front and rear disc brakes

Lighting:

Halogen headlight, taillight, turn signals (street legal)

Frame Construction:

High-tensile steel frame for rigidity and impact resistance

💡 Technology Features

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance Features:

N/A (No electronic rider aids typical for this era)

Connectivity Features:

N/A

Dashboard:

Analog speedometer, tachometer, odometer, trip meter, and indicator lights (neutral, turn signals, high beam)

🔧 Maintenance

Oil Change:

Every 3,000 km or 6 months, whichever comes first (typical, refer to manual for exact spec)

Air Filter:

Clean/replace every 6,000 km or annually (typical, refer to manual)

Spark Plug:

Inspect/replace every 12,000 km (typical, refer to manual)

Valve Clearance:

Inspect/adjust every 6,000 km or annually (typical, refer to manual)

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for exact specification and type)

Coolant:

Ethylene glycol based coolant, 50/50 mix with distilled water (refer to manual)

Common Wear Items:

Chain and sprockets, brake pads, tires, fork seals, carburetor needle and jet wear

Potential Problems:

Carburetor tuning sensitivity, occasional stator issues, kickstand switch failure (common in older bikes)

📚 Vehicle History

Kawasaki Motorcycles:

Kawasaki Heavy Industries, Ltd. has a long history in motorcycle manufacturing, known for performance and innovation.

Klx Lineage:

The KLX series is Kawasaki's line of off-road and dual-sport motorcycles, emphasizing capability and rider engagement.

Klx250 Era:

The KLX250 model has seen multiple generations and updates throughout its production history, with this manual covering a specific early iteration.

🏆 Awards & Recognition

Awards And Recognition:

The KLX250 was generally well-regarded for its versatility and off-road capability within its segment during its production years, though specific industry awards for this particular model year are not widely documented as separate entities.