Segment:
Dual-sport / Off-road motorcycle
Target User:
Enthusiasts and mechanics seeking detailed information for maintaining and repairing the KLX250 series.
Competitors 1997:
Honda XR250L, Yamaha WR250, Suzuki DR350.
Vehicle Purpose:
Versatile off-road and light street use, known for reliability and trail capability.
Manual Value Proposition:
Provides essential technical knowledge to keep this capable off-road machine running optimally, saving time and money on repairs.
Primary Coverage:
Complete repair and service for the 1997 Kawasaki KLX250 and KLX250R models.
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, disassembly, reassembly, adjustments, specifications.
Estimated Pages:
Approximately 300-400 pages (typical for this type of manual).
Type:
Factory Service Manual / Repair Manual
Format:
Digital PDF (searchable, printable)
Engine Mechanical:
Top end (cylinder head, valve train), bottom end (crankshaft, connecting rod, pistons), lubrication system, cooling system (if applicable).
Fuel System:
Carburetor assembly, fuel tank, fuel lines, fuel pump (if equipped).
Ignition System:
CDI unit, ignition coil, spark plug, wiring.
Transmission:
Gearbox disassembly, inspection, assembly, clutch operation, gear ratios.
Drivetrain:
Chain and sprockets inspection and replacement, rear wheel hub assembly.
Suspension:
Front fork (telescopic, cartridge type) disassembly, servicing, oil levels. Rear shock absorber and linkage servicing.
Brakes:
Front and rear brake systems (disc brakes), caliper service, master cylinder service, brake fluid replacement, bleeding procedures.
Electrical System:
Wiring diagrams, lighting system, battery, charging system (alternator/stator), starter motor (if electric start equipped).
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, fenders.
Routine Maintenance:
Oil change intervals, air filter cleaning/replacement, spark plug checks, chain adjustment, brake pad checks.
Troubleshooting:
Diagnostic charts for common issues (e.g., starting problems, misfires, poor performance).
Engine Repair:
Complete engine rebuild procedures, piston ring replacement, valve adjustment, gasket replacement.
Suspension Servicing:
Front fork seal replacement, fork oil change, rear shock absorber servicing.
Carburetor Tuning:
Carburetor cleaning, jetting adjustments, idle speed settings.
Electrical Diagnostics:
Wiring troubleshooting, component testing (e.g., CDI, stator output).
Wheel And Tire Service:
Tire pressure checks, spoke tensioning, wheel bearing inspection.
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds. Includes detailed torque specifications and assembly diagrams.
Engine Type:
Four-stroke, DOHC, single-cylinder
Bore X Stroke:
72.0 mm x 61.2 mm
Cooling System:
Liquid-cooled
Horsepower Approximate:
Around 26-30 HP (varies by market and tuning)
Torque Approximate:
Around 20-22 Nm (varies by market and tuning)
Carburetor:
Mikuni VM34SS (typical, exact model may vary)
Fuel Type:
Unleaded gasoline
Compression Ratio:
10.0:1 (typical)
Valve Clearance Intake:
0.04-0.08 mm (cold)
Valve Clearance Exhaust:
0.07-0.11 mm (cold)
Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate
Gear Ratios:
Detailed in manual (e.g., 1st: 2.538, 2nd: 1.875, 3rd: 1.400, 4th: 1.136, 5th: 0.958, 6th: 0.833)
Transmission Oil Type:
API SE, SF, SG, SH or SG/CD Class SAE 10W-40 (or equivalent).
Transmission Oil Capacity:
Approximately 1.8 L (with oil filter change)
Engine Oil Change:
Every 2,000-3,000 km or annually, whichever comes first.
Air Filter Cleaning:
Every 1,000-2,000 km, or more frequently in dusty conditions.
Spark Plug Check:
Every 4,000-6,000 km.
Valve Adjustment:
Every 12,000-18,000 km.
Engine Oil Type Spec:
API SE, SF, SG, SH or SG/CD Class SAE 10W-40 motorcycle oil.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, exhaust system (depending on usage).
Carburetor Perfection:
Carburetors may require periodic cleaning and adjustment, especially after long periods of disuse or exposure to dirt/water.
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long history of producing reliable and performance-oriented motorcycles, including a strong presence in off-road segments.
Klx Lineage:
The KLX line has been a staple in Kawasaki's off-road lineup, evolving from earlier models to offer improved performance and technology for trail riding and competition.
Klx250 Production Era:
The KLX250 was a popular model throughout the 1980s and 1990s, with the KLX250R being a more performance-oriented variant for off-road use.
Manufacturing:
Primarily manufactured in Japan by Kawasaki Heavy Industries.
