1993-1997 Kawasaki KLX250R KLX250 Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250R Model Code: KLX250R Year Range: 1993-1997 Generation Generation Designation: First Generation KLX250R 👋 Introduction Market Position Segment: Dual-sport / Off-road motorcycle Target...

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Type: Motorcycle

Vendor:

Sku: 603402

Tags: 1993 1994 1995 1996 1997 Kawasaki KLX Series KLX250 KLX250R Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250R

Model Code:

KLX250R

Year Range:

1993-1997

Generation

Generation Designation:

First Generation KLX250R

👋 Introduction

Market Position

Segment:

Dual-sport / Off-road motorcycle

Target Audience:

Enthusiasts, mechanics, owners seeking to maintain and repair their KLX250R

Competitive Analysis

Key Competitors:

Honda CRF250, Yamaha WR250R, Suzuki DR-Z250

Key Features

Vehicle Focus:

Robust off-road capability with street-legal features (depending on exact trim/market)

Manual Value Proposition:

Essential guide for DIY maintenance and repair, saving costs and ensuring proper upkeep

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics, Overhaul

Page Count

Estimated Page Count:

Approximately 300-400 pages (typical for this era and model)

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, as common for aftermarket manuals)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Top end (cylinder, piston, valves), bottom end (crankshaft, connecting rod, bearings), timing system, lubrication system, cooling system (radiator, hoses, fan)

Fuel System:

Carburetor (Mikuni VM34SS likely), fuel tank, fuel lines, fuel pump (if applicable), fuel filter

Ignition System:

CDI ignition, spark plug, ignition coil, stator, wiring

Transmission Drivetrain:

Clutch operation, gear shifting mechanism, gear ratios, final drive (chain and sprockets), gearbox disassembly and assembly

Suspension:

Front forks (spring rate, damping, oil level, seals), rear shock absorber (pre-load, damping, linkage system), wheel bearings

Brakes:

Front and rear disc brakes, brake caliper overhaul, master cylinder, brake lines, brake fluid specifications, bleeding procedures

Electrical System:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting (headlight, taillight, turn signals), horn, fuses, switches

Chassis Frame:

Frame inspection, steering head bearings, swingarm bearings, footpegs, handlebars

Bodywork Trim:

Seat, fuel tank, fenders, side panels, graphics

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning, brake checks

Engine Overhaul:

Top end rebuild (piston, rings, cylinder honing), bottom end rebuild (crankshaft, bearings), valve adjustment, timing chain replacement

Carburetor Service:

Disassembly, cleaning, adjustment, jetting information

Suspension Service:

Fork seal replacement, fork oil change, shock absorber service, linkage lubrication

Brake System Maintenance:

Brake pad replacement, caliper overhaul, master cylinder service, brake fluid flush and bleed

Electrical Troubleshooting:

Diagnostic procedures for starting, charging, lighting, and ignition systems, wiring harness repair

Wheel Tire Service:

Tire mounting and balancing, spoke tensioning, wheel bearing replacement

Technical Depth

Depth:

Comprehensive: Covers routine maintenance to complete engine and chassis teardown and rebuild

Diagnostics:

Detailed troubleshooting guides with symptom-based diagnosis

Specifications:

Includes all critical torque values, clearances, fluid types, and capacities

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Searchable text for quick information retrieval

Print Quality

Image Resolution:

High-resolution diagrams and illustrations suitable for printing

Binding Type

Digital Binding:

N/A (Digital)

Paper Type

Digital Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, DOHC

Displacement:

249 cc (approximately)

Bore X Stroke:

72.0 x 61.2 mm (typical, verify with manual)

Compression Ratio:

11.0:1 (typical, verify with manual)

Performance

Horsepower:

Approximately 26-30 HP (depending on tuning and specific model year)

Torque:

Approximately 2.3-2.5 kgf·m (verify with manual)

Fuel System

Carburetor Model:

Mikuni VM34SS (likely)

Fuel Type:

Unleaded gasoline

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

Specific gear ratios will be detailed in the manual

Transmission Fluid:

SAE 10W-40 API SE or SF (verify with manual for specific specification)

Transmission Oil Capacity:

Approximately 0.7 Liters (verify with manual)

📐 Dimensions

Exterior

Length:

Approx. 2,180 mm (verify with manual)

Width:

Approx. 815 mm (verify with manual)

Height:

Approx. 1,250 mm (verify with manual)

Wheelbase:

Approx. 1,425 mm (verify with manual)

Weights

Dry Weight:

Approx. 117 kg (verify with manual)

Curb Weight:

Approx. 127 kg (fully fueled, verify with manual)

Fuel Tank Capacity:

12 Liters (verify with manual)

Suspension Travel

Front Suspension Travel:

270 mm (typical for R model)

Rear Suspension Travel:

280 mm (typical for R model)

Wheels Tires

Front Tire Size:

80/100-21 51P (verify with manual)

Rear Tire Size:

110/100-18 64P (verify with manual)

Wheelbase Type:

Spoked wheels

🛡️ Safety Features

Ratings

Safety Rating:

N/A (Motorcycle safety standards focus on design and rider responsibility)

Active Features

Braking System:

Hydraulic disc brakes front and rear

Passive Features

Lighting:

Headlight, taillight, brake light, optional turn signals (depending on market)

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a 1990s era dirt bike; no modern infotainment systems are present.)

Driver Assistance

Assistance Features:

N/A (No driver assistance technologies on this model.)

Connectivity

Connectivity Features:

N/A (No connectivity features.)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 km or 6 months (typical for this era, verify with manual)

Air Filter Cleaning:

Every 1,000 km or 6 months (more frequently in dusty conditions)

Chain Adjustment Lubrication:

Every 500 km or as needed based on slack

Valve Clearance Check:

Every 6,000 km or 12 months (typical, verify with manual)

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE or SF (verify with manual for specific grade and specification)

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 (verify with manual for specific type)

Fork Oil Type:

Specific viscosity and amount detailed in manual (e.g., SAE 10W)

Known Issues

Carburetor Performance:

Older Mikuni carburetors can sometimes experience wear in throttle shafts or diaphragm issues, leading to inconsistent idle or throttle response. Proper cleaning and adjustment are key.

Suspension Seals:

Fork seals and dust wipers can degrade over time, leading to oil leaks. Regular inspection and replacement are recommended.

Cam Chain Tensioner:

While generally robust, the cam chain tensioner mechanism can sometimes require adjustment or replacement on high-mileage examples to prevent rattling.

Electrical Connectors:

Corrosion or loose connections in the electrical harness can lead to intermittent issues with lighting or ignition.

📚 Vehicle History

Brand Heritage

Kawasaki Offroad Legacy:

Kawasaki has a long history of producing capable off-road motorcycles, including the KDX series, establishing a reputation for durability and performance.

Model Evolution

Klx Lineage:

The KLX250R built upon the success of previous off-road models, offering a blend of competition-bred performance with enhanced usability for the era. It evolved into various forms, including the KLX250S (dual-sport).

Production

Production Period:

The KLX250R was produced through the 1990s, with this specific manual covering the early to mid-90s iteration.

🏆 Awards & Recognition

Recognitions

Model Awards:

While specific awards for the 1993-1997 KLX250R are not widely publicized, Kawasaki's off-road motorcycles of this era were generally well-regarded for their performance and durability in their respective classes.