Segment:
Dual-sport / Off-road motorcycle
Target Audience:
Off-road enthusiasts, trail riders, and those seeking a capable and reliable dirt bike for recreational use.
Competitors Circa 1990S:
Yamaha WR250, Honda XR250L, Suzuki DR250S.
Versatility:
The KLX250R was designed as a capable off-road machine, balancing trail performance with usability.
Engine Type:
Torquey and reliable four-stroke single-cylinder engine.
Value Proposition:
Provides essential technical knowledge for maintaining, repairing, and optimizing the KLX250R, saving time and money on servicing.
Diagnostic Tools:
Enables owners to perform detailed diagnostics, reducing reliance on external repair shops.
Engine Coverage:
Complete engine disassembly, assembly, tuning, and troubleshooting for all KLX250 variants.
Transmission Coverage:
Clutch, gearbox, shifting mechanisms, and related components.
Chassis Coverage:
Frame, suspension (front forks, rear shock absorber), steering, wheels, and tires.
Electrical Coverage:
Ignition system, lighting, charging system, starter motor, wiring diagrams, and troubleshooting.
Fuel System Coverage:
Carburetor (Mikuni VM28SS typically), fuel tank, fuel lines, and filters.
Brake System Coverage:
Front and rear disc brakes, brake lines, master cylinders, calipers, and fluid replacement.
Cooling System Coverage:
Radiator, hoses, coolant, and fan (if applicable).
Exhaust System Coverage:
Exhaust pipes, muffler, and emissions control components.
Bodywork And Trim Coverage:
Fairings, fenders, seat, and other cosmetic components.
Type:
Factory Service Manual / Workshop Manual
File Format:
Searchable PDF
Print Quality:
High-resolution scans of original documentation, suitable for printing.
Powertrain:
Includes detailed procedures for engine rebuilds, transmission overhauls, and clutch service.
Suspension And Steering:
Covers fork seal replacement, shock absorber servicing, steering bearing adjustment, and alignment.
Braking System:
Comprehensive coverage of hydraulic brake system maintenance, bleeding, and component replacement.
Electrical And Ignition:
Detailed wiring diagrams, component testing, troubleshooting guides for ignition and charging systems.
Fuel And Carburetion:
Includes carburetor tuning, jetting information, and fuel system component diagnostics.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug inspection/replacement, brake checks.
Troubleshooting:
Diagnostic charts and step-by-step guides for common performance issues, starting problems, and electrical faults.
Repair And Rebuild:
Complete disassembly, cleaning, inspection, and reassembly procedures for all major mechanical components.
Technical Specifications:
Torque values, clearances, fluid capacities, and electrical specifications for accurate servicing.
Depth:
Comprehensive, suitable for home mechanics and professional technicians alike. Covers everything from basic adjustments to full engine rebuilds.
Engine Type:
Four-stroke, SOHC, 4-valve
Displacement:
249 cc (248.9 cu in)
Bore X Stroke:
72.0 mm x 61.2 mm
Compression Ratio:
10.1:1
Cooling System:
Liquid-cooled
Horsepower Approximate:
30-32 HP (varies by market and tune)
Torque Approximate:
18-20 lb-ft (varies by market and tune)
Carburetor Type:
Mikuni VM28SS
Fuel Capacity:
8.5 Liters (2.25 Gallons)
Ignition System:
Digital CDI
Safety Certification:
N/A (Off-road vehicle, not typically subject to road safety standards)
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Frame Construction:
Strong perimeter frame designed for off-road abuse.
Ergonomics:
Designed for rider control and comfort during off-road riding.
Features:
N/A (Basic analog instrumentation: speedometer, odometer, tachometer, indicator lights).
Features:
N/A (Mechanical systems only).
Features:
N/A (No electronic connectivity features).
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first. Refer to manual for specific oil type.
Air Filter Cleaning:
Clean every 1,000 km (600 miles) or as needed depending on riding conditions.
Chain Cleaning Lubrication:
Every 500 km (300 miles) or after riding in wet conditions.
Spark Plug Inspection:
Every 3,000 km (1,800 miles).
Engine Oil:
SAE 10W-40 API SE or SF. Capacity: 1.7 L (1.8 US qt).
Coolant:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio).
Brake Fluid:
DOT 3 or DOT 4.
Carburetor Cleaning:
Mikuni VM28SS carburetor can require regular cleaning and adjustment due to its nature, especially if fuel quality is poor or bike sits for long periods.
Suspension Seals:
Fork seals can degrade over time and require replacement, particularly with hard off-road use.
Cam Chain Tensioner:
Some owners report the cam chain tensioner can become less effective over high mileage, leading to a rattling noise. Manual provides inspection and adjustment procedures.
Electrical Connections:
Corrosion or loose connections in the electrical system can cause intermittent issues; thorough inspection is recommended.
Kawasaki Offroad Legacy:
Kawasaki has a long history of producing competitive off-road motorcycles, including successful motocross and enduro models.
Klx Lineage:
The KLX250 series evolved from earlier Kawasaki dual-sport and off-road platforms, offering a blend of performance and reliability.
Manufacturing Period:
1993-1997, representing a specific generation of the KLX250 model.
