Model Segment:
Dual-sport motorcycle, known for its versatility in off-road and on-road use.
Competitors 1994:
Honda XR250L, Yamaha XT250, Suzuki DR250SE.
Kawasaki Klx250R Strengths:
Robust construction, capable suspension, reliable engine for its class, strong off-road performance, user-friendly maintenance.
Target Audience:
DIY mechanics, restoration enthusiasts, owners seeking to maintain or repair their 1994 Kawasaki KLX250R.
Systems Covered:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Transmission, Clutch, Chassis, Suspension (Front & Rear), Brakes (Front & Rear), Electrical System (Wiring Harness, Lighting, Ignition), Frame, Wheels, Tires, Bodywork, Specifications, Troubleshooting, Maintenance.
Manual Type:
Full Service Repair Manual
Format:
Digital (PDF/eBook)
Engine Service:
Complete engine overhaul, piston replacement, cylinder head service, valve adjustment, camshaft timing, crankshaft inspection, internal component torque specifications, seals and gasket replacement.
Fuel System Service:
Carburetor disassembly, cleaning, adjustment, jetting information, fuel pump (if applicable), fuel lines, fuel filter replacement.
Transmission Service:
Clutch operation, gearbox disassembly and reassembly, gear inspection, shift mechanism, transmission fluid type and capacity.
Electrical System Service:
Wiring diagrams, ignition system troubleshooting, lighting circuits, battery maintenance, charging system analysis, starter motor, switches and controls.
Suspension Service:
Front fork overhaul (oil change, seal replacement, spring rates), rear shock absorber service, linkage maintenance.
Brake Service:
Front and rear brake pad replacement, caliper service, brake fluid flush and bleed, master cylinder inspection, brake hose condition.
Chassis And Frame Service:
Frame inspection for damage, steering head bearing service, swingarm pivot maintenance, wheel bearing replacement.
Preventative Maintenance:
Scheduled maintenance tasks, lubrication points, filter replacement intervals, chain adjustment and lubrication.
Troubleshooting Guides:
Diagnostic procedures for common issues, symptom-based problem solving, electrical system troubleshooting charts.
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment.
Special Tool Requirements:
Identification and usage of specialized tools required for specific procedures.
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance and fluid changes to complete engine rebuilds and advanced troubleshooting.
Engine Type:
4-stroke, Single-cylinder, SOHC, 4-valve
Bore X Stroke:
70.0 mm x 61.3 mm
Compression Ratio:
10.0:1
Cooling System:
Liquid-cooled
Horsepower Estimated:
30-34 HP (at crankshaft, estimated)
Torque Estimated:
18-20 lb-ft (at crankshaft, estimated)
Carburetor Type:
Keihin CVK34 (Constant Velocity)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Oil Capacity With Filter:
1.8 L (approximate, refer to manual for exact specification)
Oil Type:
SAE 10W-40 API SE or SF (refer to manual for specific recommendations)
Safety Standards:
Not applicable for motorcycle safety ratings in the same manner as automobiles; emphasis on rider safety through design and maintenance.
Braking System:
Front: Disc brake, Rear: Disc brake (typical for KLX250R of this era)
Lighting System:
Headlight, Taillight, Brake lights, Turn signals (front and rear), Indicators.
Infotainment Features:
N/A (Basic motorcycle design, no integrated infotainment systems).
Driver Assistance Features:
N/A (No electronic driver assistance systems).
Connectivity Features:
N/A (Basic electrical system).
Oil Change Interval:
Every 3,000 km or 6 months (refer to manual for exact recommendation)
Air Filter Cleaning:
Every 2,000 km or as needed in dusty conditions
Spark Plug Replacement:
Every 6,000 km (check gap and condition regularly)
Chain Adjustment Lubrication:
Every 1,000 km or as needed
Valve Clearance Check:
Every 6,000 km
Coolant Type:
Ethylene glycol-based coolant (50% mixture with distilled water), refer to manual for specific type.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification)
Carburetor Wear:
Diaphragm wear in CVK carburetors can lead to performance issues. The manual provides detailed rebuilding procedures.
Suspension Seals:
Fork seal leaks are common with age and usage; the manual details their replacement.
Clutch Cable Adjustment:
May require periodic adjustment for proper engagement and disengagement.
Kawasaki Motorcycles:
Kawasaki Heavy Industries is a renowned Japanese manufacturer with a long history in motorcycle production, known for innovation and performance across various segments, including off-road and sport bikes.
Klx Series Development:
The KLX line has been a staple for Kawasaki in the dual-sport and motocross categories. The KLX250, in particular, has evolved through various iterations, with the 'R' designation often signifying a more off-road-oriented version.
Klx250 Production Years:
The KLX250 model line has been in continuous production in various forms since the 1970s, with significant updates throughout the decades.
Manufacturing Location:
Japan (typically)
