Kawasaki KLX250 Service Manual Repair 1993-2005 KLX250R

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Type: Motorcycle

Vendor:

Sku: 140353

Tags: 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 H Series Kawasaki KLX250 KLX250R Motorcycle Motorcycles

Product variants

Description

The KLX250 series motorcycles, produced between 1993 and 2005, represent a robust and versatile line of off-road and dual-sport machines. With variants like the KLX250-D for off-road use, KLX250-E as a dual sport, and the KLX250-J D-Tracker for supermoto applications, these models cater to a wide range of riding preferences and terrains. Known for engineering quality and reliability, the KLX250 offers dependable performance and capability, making it a favored choice for both recreational riders and those seeking a capable all-around motorcycle. This comprehensive 411-page factory repair and service manual provides detailed guidance for owners, DIY mechanics, and professional technicians. It covers all essential aspects of maintenance and repair, including in-depth procedures for engine systems, chassis components, electrical systems, and bodywork. The manual includes scheduled maintenance, fluid changes, component teardowns and rebuilds, troubleshooting diagnostics for common issues, and technical specifications. Its searchable format with clickable chapters ensures efficient access to information, empowering users to effectively maintain and repair their KLX250 motorcycles across various global regions.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250 / KLX250R

Model Variants:

KLX250-D (Off-road), KLX250-E (Dual Sport), KLX250-G (Europe), KLX250-H (Europe/Australia Dual Sport), KLX250-J D-Tracker (Europe/Australia Supermoto)

Production Years Covered:

1993, 1994, 1995, 1996, 1999, 2000, 2001, 2002, 2003, 2004, 2005

👋 Introduction

Market Position

Target Audience:

Owners, DIY mechanics, and professional technicians working on Kawasaki KLX250 series motorcycles from 1993-2005.

Competitive Analysis

Value Proposition:

Provides essential, factory-backed repair and maintenance information, covering a significant range of model years and variants, enabling users to perform comprehensive service and repairs, thus saving on dealership costs.

Key Features

Manual Features:

Factory-level detail, comprehensive coverage of multiple model variants, detailed illustrations and diagrams, torque specifications, troubleshooting guides, and a user-friendly digital format.

Seller Support

Replacement Policy:

Free replacement offered for lost manuals upon contact.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (specific models indicate regional variations like Europe/Australia)

Page Count

Page Count:

411 pages

Manual Type

Manual Type:

Factory Repair Manual / Service Manual

Language

Language:

English (implied by product description and common manual formats)

Format

File Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine Systems:

Complete engine teardown and rebuild, carburetor (including pilot jet, main jet, mixture screw), ignition system, starting system, lubrication system, cooling system (coolant replacement, radiator, coolant change), valve clearance adjustment, cylinder, piston, crankshaft, camshafts, connecting rod, drive train, primary reduction gear, transmission.

Chassis Systems:

Frame, suspension (front forks, rear suspension, linkage, struts, swingarm, swinger), brakes (front and rear, rotors, pads), wheels, tires, steering, electrical system (stator, magneto, battery, rectifier, regulator, switches, starter, coils, lights).

Bodywork And Accessories:

Fenders, plastics, seat, handlebars, fuel tank, exhaust system, body panels, D-Tracker conversion aspects (supermoto).

Procedures Included

Maintenance Procedures:

Scheduled maintenance, fluid changes (oil, coolant), filter replacements, chain adjustment, lubrication points, valve clearance checks and adjustments, tire pressure checks, brake adjustments.

Repair Procedures:

Complete teardown and rebuild of all major mechanical and electrical components, engine overhauls, transmission repairs, suspension overhauls, brake system repairs, electrical system troubleshooting and repair.

Troubleshooting Guidance:

Diagnostic procedures for common problems, no spark issues, starting problems, electrical faults, engine performance issues, error code interpretation (if applicable to the era), troubleshooting the carburetor and fuel system.

Performance Enhancements:

Information related to specific model variants like the D-Tracker (supermoto) may include details relevant to performance tuning or modifications, pilot jet/main jet selection, carburetor tuning.

Technical Depth

Depth Of Coverage:

Comprehensive. Covers complete teardown and rebuilds, detailed part diagrams, torque specifications for all fasteners, diagnostic procedures, and repair instructions for all major systems.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printable:

Yes (no restrictions)

Binding Type

Binding Type:

Digital Download (Not applicable to physical binding)

Paper Type

Paper Type:

N/A (Digital)

Usability Features

Searchable:

Navigation:

Clickable chapters

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder (liquid-cooled, DOHC, 4 valves for most variants)

Displacement:

Approximately 249cc (specific variants may have minor differences)

Bore X Stroke:

Commonly 66.0 mm x 72.0 mm (refer to specific model year for exact figures).

Compression Ratio:

Typically around 11.0:1 to 11.3:1 (refer to specific model year).

Performance

Horsepower:

Estimated 20-30 HP (specific output varied by market regulations and tuning, often around 23-26 HP).

Torque:

Approximately 20-23 Nm (refer to specific model year).

Fuel System

Fuel Delivery:

Carburetor (e.g., Keihin CVK34 or similar) for most off-road and dual-sport variants. Some European models might have had specific carburetors.

Carburetor Specifications:

Includes details on main jet, pilot jet, needle, air screw, and float level adjustments for optimal tuning and performance.

Engine Oil

Recommended Oil Viscosity:

Typically SAE 10W-40 or 20W-50 (check manual for precise recommendations based on ambient temperature).

Oil Capacity:

Around 1.7 - 1.9 Liters (with filter change) - confirm with manual for specific year.

🔧 Transmission

Standard

Transmission Type:

6-speed manual transmission

Features

Gear Ratios:

Specific gear ratios are detailed within the manual for performance optimization and component identification.

Clutch Type:

Wet multi-plate clutch

Transmission Fluid

Transmission Fluid Type:

Engine oil serves as transmission fluid (refer to manual for specific viscosity and API classification).

📐 Dimensions

Exterior

Overall Length:

Varies by model variant, typically around 2150-2200 mm.

Overall Width:

Varies by model variant, typically around 800-850 mm.

Overall Height:

Varies by model variant, typically around 1150-1200 mm.

Weights

Dry Weight:

Approximately 114-120 kg (varies significantly by model variant and equipment).

Curb Weight:

Approximately 126-135 kg (with all necessary fluids and ready to ride).

Wheels Tires

Front Tire Size:

Commonly 3.00-21 or 80/100-21.

Rear Tire Size:

Commonly 4.60-17 or 110/100-17 (dual sport/off-road) or 130/70-17 (supermoto).

Wheelbase:

Approximately 1430-1435 mm.

Fuel Capacity

Fuel Tank Capacity:

Around 7.7 - 11 Liters (varies by model variant).

🛡️ Safety Features

Ratings

Safety Features:

As a motorcycle, safety features are primarily rider-dependent and revolve around the quality of components like brakes, suspension, and chassis stability. The manual provides information to maintain these systems in optimal condition.

Active Features

Braking System:

Hydraulic disc brakes front and rear (specific rotor diameter and caliper type detailed in manual).

Passive Features

Frame Construction:

High-tensile steel perimeter frame, designed for rigidity and off-road durability.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable for this era of dual-sport/off-road motorcycles. Focus is on mechanical and electrical functionality.

Driver Assistance

Rider Aids:

No electronic rider aids like ABS or traction control are standard on these models from this period.

Connectivity

Connectivity Features:

Not applicable.

Electrical Components

Ignition System:

CDI (Capacitor Discharge Ignition) or similar electronic ignition system, managed by a magneto and possibly an ECU. Manual covers ignition coil testing, timing checks, and troubleshooting 'no spark' conditions.

Charging System:

Stator and rectifier/regulator system for charging the battery. Manual provides testing procedures for these components.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 2,000-3,000 km or 6 months, whichever comes first (refer to manual for specific interval).

Valve Adjustment Interval:

Generally recommended every 6,000-10,000 km or annually (check manual for precise interval and procedure).

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment are crucial (intervals specified in manual).

Fluid Specifications

Coolant Type:

Permanent type antifreeze/coolant (mix of ethylene glycol and distilled water, typically 50/50). Check manual for specific Kawasaki coolant recommendations.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, brake pads, wheel bearings, suspension seals, and carburetor components can be common wear items depending on riding conditions and maintenance.

Potential Performance Tuning Areas:

Carburetor tuning (jets, needle) is a frequent area for modification to optimize performance, especially when changing exhaust or airbox configurations. Valve clearance is critical for engine health.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing robust and capable off-road and dual-sport motorcycles, known for their performance and durability.

Model Evolution

Klx Lineage:

The KLX line has been a staple for Kawasaki in the dual-sport and off-road segments. The KLX250, in particular, has evolved to cater to various riding styles, from trail riding to more street-oriented supermoto applications (D-Tracker).

Production

Manufacturing Origin:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Model Reputation:

The KLX250 is generally well-regarded for its reliability, off-road capability, and versatility as a dual-sport platform. Specific awards are not prominently documented, but the model series has maintained a strong following.