🏷️ Basic Information

Make:

Kawasaki

Model:

KLX250-D2

Year:

1994

Product Type:

Factory Service Repair Manual

Chassis Code:

KL250-D2

👋 Introduction

Market Position:

The Kawasaki KLX250-D2 was a capable dual-sport motorcycle, popular for its off-road prowess and versatility for on-road use, fitting into the lightweight adventure and trail riding segment.

Competitors:

Competed with models like the Honda XR250L, Yamaha XT225, and Suzuki DR250S of the era.

Key Features:

Liquid-cooled engine, robust suspension, lightweight chassis, disc brakes front and rear, and long-travel suspension suitable for varied terrain.

📋 Manual Details

Primary Coverage:

Complete repair and maintenance of the 1994 Kawasaki KLX250-D2

Page Count:

Approximately 400-500 pages (estimated based on typical factory service manuals of the era)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Likely Print (Original Factory Publication) or High-Quality PDF Scan

📖 Manual Coverage

Engine System:

Detailed diagnostics, disassembly, assembly, inspection, and repair of the 249cc four-stroke engine.

Fuel System:

Carburetor tuning, overhaul, and component testing; fuel tank, lines, and petcock.

Ignition System:

CDI unit, ignition coil, spark plug, stator, and wiring diagrams.

Lubrication System:

Oil pump, oil filter, oil passages, and oil change procedures.

Cooling System:

Air cooling system, cylinder head cooling fins, and related components.

Transmission System:

Gearbox disassembly, inspection, assembly, clutch operation, and maintenance.

Drivetrain System:

Final drive chain adjustment and replacement, sprocket inspection.

Suspension System:

Front fork disassembly, service, seal replacement, oil levels, and rear shock absorber adjustment and service.

Braking System:

Front and rear brake system inspection, pad replacement, fluid bleeding, caliper service, and drum brake adjustment.

Wheel And Tire System:

Wheel bearing inspection and replacement, spoke tensioning, tire pressure recommendations.

Electrical System:

Wiring diagrams, battery maintenance, lighting system, horn, and starter system.

Chassis And Frame:

Frame inspection, steering head bearing service, and component mounting.

Bodywork And Trim:

Panel removal and installation, seat maintenance, and fender inspection.

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for common issues.

Engine Overhaul:

Complete engine disassembly, internal component inspection (piston, rings, valves, crankshaft), and reassembly instructions.

Carburetor Rebuild:

Step-by-step instructions for dismantling, cleaning, replacing jets, and reassembling the carburetor.

Suspension Rebuild:

Detailed procedures for fork seal replacement, damper rod service, and rear shock absorber rebuild.

Brake System Service:

Pad replacement, caliper servicing, piston seal replacement, and brake fluid flush/bleed.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, testing components with a multimeter.

Wheel Truing:

Instructions for checking and adjusting spoke tension for proper wheel alignment.

Depth:

Comprehensive from basic rider maintenance to full engine rebuilds and electrical system diagnostics.

📊 Manual Specifications

File Format:

PDF (if digital) - Searchable text, high-resolution scans of original pages.

Print Quality:

High-resolution reproductions of original factory diagrams and text.

Binding Type:

Staple-bound or perfect bound (for printed copies)

Paper Type:

Durable paper stock suitable for workshop environments (for printed copies)

⚙️ Engine Specifications

Engine Type:

4-stroke, DOHC, 4-valve, Single Cylinder

Displacement:

249 cc

Bore X Stroke:

72.0 mm x 61.2 mm

Compression Ratio:

10.0:1

Horsepower:

Approximately 20-22 HP (estimated)

Torque:

Approximately 14-16 lb-ft (estimated)

Carburetor:

Mikuni VM28SS (single) or similar

Fuel Type:

Unleaded gasoline

Ignition:

Digital CDI (Capacitor Discharge Ignition)

Cooling:

Liquid-cooled

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multi-disc, manual operation

Gear Ratios:

Specific gear ratios detailed in the manual for each gear.

Final Drive:

O-ring sealed chain, 520 pitch

📐 Dimensions

Length:

Approx. 2190 mm (86.2 in)

Width:

Approx. 830 mm (32.7 in)

Height:

Approx. 1235 mm (48.6 in)

Wheelbase:

Approx. 1425 mm (56.1 in)

Ground Clearance:

Approx. 265 mm (10.4 in)

Dry Weight:

Approx. 127 kg (280 lbs)

Wet Weight:

Approx. 138 kg (304 lbs) (with all fluids)

Fuel Capacity:

Approx. 11 Liters (2.9 US gal)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle safety is primarily rider-dependent and dictated by equipment)

Active Safety:

Disc brakes front and rear for effective stopping power, capable suspension for stability.

Passive Safety:

Sturdy frame construction, appropriate lighting for visibility.

💡 Technology Features

Infotainment Features:

N/A (This model predates modern infotainment systems; features are mechanical and analog).

Driver Assistance Features:

N/A (No electronic driver assistance features).

Connectivity Features:

N/A (No electronic connectivity features).

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 km (1,860 miles) or 6 months, whichever comes first (refer to manual for exact specification).

Air Filter Service:

Clean every 2,000 km (1,240 miles) or as needed based on riding conditions; replace as necessary.

Spark Plug Inspection:

Inspect every 4,000 km (2,480 miles); replace as needed.

Chain Maintenance:

Lubricate and adjust every 1,000 km (620 miles) or after washing/wet riding.

Engine Oil Type:

SAE 10W-40 API SG or SH, JASO MA compliant motorcycle oil (verify specific grade in manual).

Coolant Type:

Ethylene glycol-based antifreeze mixture (50/50 with distilled water) for liquid-cooled engines (verify in manual).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (verify specific grade in manual).

Fork Oil Type:

Specific weight fork oil, typically SAE 10W (verify in manual for quantity and viscosity).

Common Issues:

Carburetor jetting can be sensitive to altitude and modifications. Fork seals can leak over time. Cam chain tensioner wear can sometimes lead to rattling. Regular maintenance is key to longevity.

📚 Vehicle History

Brand Heritage:

Kawasaki has a long history of producing robust and performance-oriented motorcycles, particularly in the off-road and dual-sport segments with models like the KLR and KLX series.

Model Evolution:

The KLX250 line has evolved significantly over the years, with the 1994 D2 model representing a period of refinement for the liquid-cooled, 250cc dual-sport offering, building on previous generations and paving the way for subsequent models.

Production Period:

The KLX250-D2 was part of the KLX250 series, which saw production from the late 1970s through to the present day in various iterations.

🏆 Awards & Recognition

Recognitions:

While specific awards for the 1994 KLX250-D2 might not be readily cataloged, the KLX series as a whole has consistently received praise for its off-road capability and reliability within the dual-sport community.