Vehicle Segment:
Dual-Sport / Off-Road Motorcycle
Target Audience:
Enthusiasts, mechanics, owners performing self-maintenance and repairs
Competitors:
Honda XR250L, Yamaha TT-R250, Suzuki DR250SE
Vehicle Strengths:
Robustness, off-road capability, simplicity, reliability
Manual Value Proposition:
Essential resource for maintaining peak performance and longevity of the KLX250R
Engine:
Engine disassembly, assembly, inspection, troubleshooting, performance tuning
Fuel System:
Carburetor, fuel lines, fuel pump (if applicable), fuel tank maintenance
Cooling System:
Radiator, fan, coolant flushing, thermostat, hoses
Exhaust System:
Muffler, exhaust pipe inspection and replacement
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism
Suspension:
Front forks (telescopic, hydraulic), rear shock absorber, linkage maintenance, adjustments
Brakes:
Hydraulic front disc brake, rear drum brake maintenance, bleeding, pad/shoe replacement
Electrical System:
Ignition system, lighting, battery, charging system, starter motor, wiring diagrams, troubleshooting
Chassis Frame:
Frame inspection, swingarm, steering head bearing maintenance
Wheels Tires:
Spoke wheel maintenance, tire pressure, replacement
Maintenance:
Routine checks, lubrication, filter replacements, spark plug service, chain adjustment
Troubleshooting:
Diagnostic procedures for common mechanical and electrical faults, symptom-based guides
Repair:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly
Rebuilds:
Detailed procedures for engine, transmission, and suspension component overhauls
Adjustments:
Carburetor tuning, chain slack, brake lever free play, suspension settings
Torque Specifications:
Critical torque values for all fasteners and engine components
Depth:
Comprehensive: from basic maintenance to complete engine and transmission rebuilds
Diagnostic Focus:
Advanced troubleshooting guides with fault codes and diagnostic flowcharts (where applicable)
Electrical Detail:
Detailed wiring diagrams for all electrical circuits, component testing
Engine Type:
Four-stroke, DOHC, single-cylinder
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 mm x 61.2 mm (2.83 in x 2.41 in)
Cooling System:
Liquid-cooled
Compression Ratio:
10.0:1 (typical)
Horsepower:
Approx. 22-25 HP (at crank, varies by year/market)
Torque:
Approx. 16-18 lb-ft (at crank, varies by year/market)
Carburetor Type:
Keihin CVK34 (typical)
Fuel Type:
Unleaded gasoline
Oil Type:
SAE 10W-40, API SF or SG (refer to manual for exact specs)
Oil Capacity:
Approx. 1.7 L (1.8 US qt) with filter change
Oil Change:
Every 3,000 km (2,000 miles) or 6 months (refer to manual for specific conditions)
Air Filter:
Clean every 1,000 km (600 miles), replace as needed
Spark Plug:
Inspect every 3,000 km (2,000 miles), replace as needed
Chain Maintenance:
Lubricate and adjust every 500 km (300 miles)
Valve Clearance:
Inspect every 6,000 km (4,000 miles)
Coolant Type:
Permanent type antifreeze, mix 50% ethylene glycol and 50% distilled water
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Fork Oil:
SAE 10W (refer to manual for specific quantity and grade)
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, exhaust gaskets.
Potential Problems:
Carburetor jetting can be sensitive to altitude and modifications. Older units may require carburetor cleaning and rebuild.
Kawasaki Motorcycles:
Kawasaki has a long history of producing performance-oriented motorcycles, particularly in off-road and dual-sport segments.
Klx Lineage:
The KLX series represents Kawasaki's commitment to the dual-sport market, building on previous successful off-road platforms.
Production Period:
The KLX250R was a significant model in the early to mid-1990s, offering a balance of off-road prowess and street legality.
