Segment:
Dual-sport motorcycle, targeting off-road enthusiasts and light trail riding. Competed in a segment with Yamaha XT250 and Suzuki DR250.
Features:
Lightweight chassis, capable suspension, reliable 4-stroke engine, electric start, suitable for both on-road commuting and off-road excursions.
Engine:
Complete Engine Overhaul, Carburetor Tuning, Ignition System, Cooling System
Transmission:
Clutch Operation, Gearbox Disassembly/Reassembly, Shift Mechanism
Chassis:
Frame, Suspension (Front Forks, Rear Shock), Steering System, Wheels and Tires
Electrical:
Wiring Diagrams, Lighting System, Ignition System, Starting System, Charging System
Brakes:
Front and Rear Brake System Maintenance, Hydraulic System Service, Pad Replacement
Bodywork:
Panel Removal/Installation, Seat, Fuel Tank, Fender
Troubleshooting:
Diagnostic Procedures, Common Faults and Solutions
Estimated Pages:
Approximately 300-400 pages (typical for this era and coverage).
Type:
Service and Repair Manual
Engine Systems:
249cc, liquid-cooled, DOHC, 4-stroke single-cylinder engine. Covers piston, rings, cylinder, head, valves, timing chain, lubrication system, cooling system, and carburetor (likely Keihin CVK).
Transmission Systems:
6-speed constant mesh transmission. Includes clutch assembly, gearbox lubrication, shifting mechanism, and final drive (chain).
Suspension Steering:
Front: Telescopic forks with adjustable compression/rebound. Rear: Uni-Trak single shock with adjustable preload, compression, and rebound damping.
Braking Systems:
Front: Hydraulic disc brake. Rear: Hydraulic disc brake. Covers master cylinders, calipers, lines, and fluid specifications.
Electrical Systems:
AC magneto ignition system, DC electric starter, lighting circuits (headlight, taillight, indicators, brake light), battery charging system, and instrument panel.
Maintenance Procedures:
Oil change intervals, oil filter replacement, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid flush, coolant flush.
Repair Procedures:
Engine top-end rebuild (piston, rings, cylinder head), carburetor disassembly, cleaning, and adjustment, clutch plate replacement, fork seal replacement, shock absorber service, brake caliper overhaul, wheel bearing replacement.
Troubleshooting Guides:
Diagnosis of starting problems, engine performance issues, electrical system faults, brake system malfunctions, and suspension noise.
Depth:
Comprehensive: Covers routine maintenance, diagnostics, component replacement, and complete engine/transmission rebuilds. Includes detailed torque specifications, clearances, and schematics.
Engine Type:
249cc, Liquid-cooled, 4-stroke, DOHC, Single-cylinder
Bore X Stroke:
72.0 mm x 61.2 mm
Compression Ratio:
11.0:1
Horsepower Estimated:
Approximately 26-28 HP (at crank)
Torque Estimated:
Approximately 18-20 lb-ft (at crank)
Carburetor:
Keihin CVK34 (Constant Velocity Carburetor)
Fuel Capacity:
10.0 L (2.6 US gal)
Oil Type:
API SG, SAE 10W-40 motorcycle oil recommended.
Oil Capacity:
1.7 L (with filter change), 1.5 L (without filter change)
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water.
Coolant Capacity:
Approximately 0.8 L
Gearbox:
6-speed, constant mesh
Clutch Type:
Wet multi-disc
Final Drive:
Sealed O-ring chain
Gear Ratios:
1st: 2.600, 2nd: 1.750, 3rd: 1.333, 4th: 1.100, 5th: 0.913, 6th: 0.777 (Typical values, exact may vary)
Transmission Oil Type:
API SG, SAE 10W-40 motorcycle oil (shared with engine sump).
Length:
Approximately 2180 mm (85.8 in)
Width:
Approximately 830 mm (32.7 in)
Height:
Approximately 1195 mm (47.0 in)
Wheelbase:
Approximately 1430 mm (56.3 in)
Dry Weight:
Approximately 135 kg (297.6 lbs)
Wet Weight:
Approximately 145 kg (319.7 lbs)
Gvwr:
Not specified in product data, consult full manual.
Crash Test Ratings:
N/A (Motorcycles are not typically rated by consumer safety organizations like NHTSA).
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
Lighting:
Headlight, taillight, brake light, and turn signals for visibility.
Frame Construction:
Steel semi-double cradle frame for rider protection and stability.
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators, oil warning light, engine temperature indicator (if applicable).
Rider Aids:
None (This is a 1993 model, prior to widespread electronic rider aids).
Features:
N/A (No electronic connectivity features).
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months.
Oil Filter Replacement:
Every 6,000 km (3,600 miles) or 12 months.
Air Filter Cleaning:
Every 1,000 km (600 miles), clean and re-oil.
Spark Plug Inspection:
Every 3,000 km (1,800 miles).
Chain Lubrication Adjustment:
Every 500 km (300 miles) or after riding in wet conditions.
Brake Fluid Replacement:
Every 24 months or as needed.
Valve Clearance Check:
Every 6,000 km (3,600 miles).
Engine Oil Spec:
API SG, JASO MA, SAE 10W-40
Brake Fluid Spec:
DOT 3 or DOT 4.
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, carburetor jets (can be prone to clogging if fuel is not clean).
Engine Considerations:
Proper jetting for altitude and temperature is crucial for optimal performance and engine longevity. Regular cleaning of the air filter is vital.
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long-standing reputation for performance and innovation in motorcycle manufacturing since the 1960s, with a strong lineage in off-road and dual-sport motorcycles.
Klx Series:
The KLX series has been a staple for Kawasaki in the dual-sport market. The KLX250, evolving through various iterations, has consistently offered a balance of off-road capability and street legality.
Production Period:
The KLX250 model line has seen production across multiple decades, with significant updates and redesigns occurring periodically. The 1993 model represents a specific generation within this evolution.
