Segment:
Dual-sport / Off-road motorcycle
Target Audience:
Enthusiasts, owners, and mechanics requiring detailed repair and maintenance information for the 1993 Kawasaki KLX250/KLX250R.
Key Competitors Era:
Honda XR250R, Yamaha XT250/TT250R, Suzuki DR250S/DR250SE.
Vehicle Focus:
Robust, reliable, and capable off-road performance with street legality (depending on specific configuration and local regulations).
Manual Value Proposition:
Provides the in-depth technical knowledge required to maintain, repair, and optimize the performance of this classic Kawasaki dual-sport motorcycle.
Engine:
Complete overhaul, top-end, bottom-end, lubrication system, cooling system, fuel system, ignition system, exhaust system, emissions controls.
Transmission:
Clutch, gearbox, shift mechanism, lubrication, repair procedures.
Chassis:
Frame, suspension (front forks, rear shock), steering, wheels, hubs, spokes, braking system (front and rear), final drive (chain and sprockets).
Electrical:
Ignition system, lighting system, charging system (stator, regulator/rectifier, battery), starting system, wiring diagrams, component testing.
Bodywork:
Fairings, seat, fuel tank, fenders, protective components.
Maintenance:
Regular servicing, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks and adjustments, brake pad replacement, fluid changes.
Repair:
Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper servicing, electrical component diagnosis and repair, carburetor tuning and rebuilding.
Troubleshooting:
Systematic diagnosis of common and uncommon problems, fault finding charts, symptom-based troubleshooting guides.
Diagnostics:
Component testing procedures, specifications for testing (e.g., resistance, voltage, current), timing checks, compression testing.
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine and transmission disassembly/reassembly, including detailed torque specifications and tolerances.
Digital Format:
PDF (Portable Document Format)
Quality:
High-resolution scans, clear text and diagrams, suitable for printing individual pages or the entire document.
Binding:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
Text Search:
Typically searchable text within the PDF, allowing for quick keyword lookup.
Type:
Four-stroke, DOHC, liquid-cooled, single-cylinder
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm (typical for this generation)
Compression Ratio:
Typically around 11.0:1 (check specific model variant)
Horsepower:
~25-30 HP (at crankshaft, estimated for the era)
Torque:
~20-23 Nm (at crankshaft, estimated for the era)
Carburetor:
Keihin CVK34 (or similar dual-throat carburetor) with accelerator pump.
Fuel Type:
Unleaded gasoline
Fuel Capacity:
~9.0 - 10.0 Liters (approximate, including reserve)
Type:
Digital CDI (Capacitor Discharge Ignition)
Type:
Liquid-cooled (radiator and fan)
Type:
Single muffler with catalytic converter (for street versions).
Type:
6-speed constant mesh
Clutch:
Wet multi-disc, cable operated.
Final Drive:
O-ring sealed chain, 520 pitch (typical).
Engine Oil Capacity:
~1.5 - 1.8 Liters (with filter change, check manual for exact spec)
Engine Oil Type:
SAE 10W-40 API SG or higher (typical motorcycle oil recommendation).
Length:
~2180 mm (approximate)
Width:
~820 mm (approximate)
Height:
~1220 mm (approximate)
Wheelbase:
~1430 mm (approximate)
Dry Weight:
~127 kg (KLX250R, approximate)
Curb Weight:
~139 kg (KLX250, approximate, with fluids)
Front Suspension Travel:
~270 mm (KLX250R, typical for competition models)
Rear Suspension Travel:
~280 mm (KLX250R, typical for competition models, Uni-Trak system)
Front Tire:
80/100-21 (typical off-road size)
Rear Tire:
100/90-18 or 110/90-18 (typical off-road size)
Crash Test Ratings:
N/A (Motorcycles are not typically subjected to standardized crash testing like cars)
Braking System:
Front: Hydraulic disc brake. Rear: Hydraulic disc brake. (Specifications for caliper type, rotor size, and fluid type are detailed in the manual).
Lighting:
Headlight, taillight, brake light, turn signals (depending on street-legal configuration).
Oil Change Interval:
Every 3,000 km or 6 months (typical recommendation, consult manual for specifics).
Air Filter Cleaning Interval:
Every 1,000 km or as needed based on riding conditions (off-road requires more frequent cleaning).
Valve Clearance Check Interval:
Every 6,000 km or 12 months (typical recommendation).
Spark Plug Replacement Interval:
Every 10,000-12,000 km or annually (check manual for plug type and gap).
Brake Fluid Type:
DOT 3 or DOT 4 (check reservoir cap or manual).
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water (typically green or orange type, consult manual).
Carburetor Performance:
Early models could be sensitive to jetting changes, and the CVK carburetor may require periodic cleaning and adjustment for optimal performance, especially at altitude or with modifications.
Suspension Wear:
Fork seals and rear shock bushings/seals can wear over time, leading to leaks and diminished damping performance, especially with hard off-road use.
Exhaust Header Pipe:
Can sometimes develop cracks due to heat cycles and vibration; professional welding may be required.
Clutch Adjustment:
Routine adjustment of clutch cable free play is necessary for proper clutch engagement and longevity.
Wheel Bearing Service:
Wheel bearings require periodic inspection, cleaning, and re-greasing or replacement, particularly after exposure to water or dirt.
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for performance and innovation, particularly in off-road and racing segments.
Klx Lineage:
The KLX series has been a cornerstone of Kawasaki's dual-sport and off-road offerings for decades, evolving from earlier models like the KDX and KE series. The KLX250, introduced in the 1970s, saw significant updates over the years, with the 1993 model representing a refined iteration of its off-road prowess.
Manufacturing Location:
Japan (typically)
Production Era:
The KLX250 line has seen multiple generations and updates, with the 1993 model belonging to a period where air-cooled and liquid-cooled variants coexisted before later models focused on liquid cooling and more modern designs.
Model Specific Awards:
N/A (While the KLX250R was a respected off-road machine, specific major awards for this model year are not widely documented. Its reputation is built on performance and durability.)
Consumer Ratings Era:
Generally well-regarded for its off-road capability, reliability, and smooth power delivery for its displacement class at the time of its release.
Emissions Compliance:
Subject to emissions regulations of the time and region of sale; manual will detail any specific compliance or adjustment procedures.
