Kawasaki 250 KLX E1 1993 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 Year: 1993 Codes Model Code: KLX250-E1 👋 Introduction Market Position Vehicle Class: Dual-sport / Off-road motorcycle Target Audience: Enthusiasts seeking a capable...

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Type: Motorcycle

Vendor:

Sku: 603469

Tags: 1993 250 KLX E1 Kawasaki KLX Series Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250

Year:

Codes

Model Code:

KLX250-E1

👋 Introduction

Market Position

Vehicle Class:

Dual-sport / Off-road motorcycle

Target Audience:

Enthusiasts seeking a capable and reliable off-road machine with street legality

Competitive Analysis

Competitors Era:

Honda CRF series, Yamaha WR series, Suzuki DR series, KTM EXC series

Key Features

Design Philosophy:

Robust construction, reliable single-cylinder engine, capable suspension for varied terrain

📋 Manual Details

Coverage Areas

Primary Focus:

Workshop Service and Repair

Page Count

Estimated Pages:

Manual Type

Type:

Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, though physical printed copies also common for this era)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, repair, and reassembly (top end, bottom end, cooling, lubrication)

Transmission:

Gearbox operation, clutch service, shift mechanism, lubrication, and troubleshooting

Fuel System:

Carburetor service (cleaning, adjustment, rebuilding), fuel lines, fuel tank, fuel pump (if applicable)

Ignition System:

CDI ignition, spark plug, ignition coil, timing procedures

Cooling System:

Radiator, hoses, thermostat, coolant specifications and capacities

Exhaust System:

Exhaust pipe, muffler, gaskets, inspection and replacement

Chassis And Frame:

Frame inspection, swingarm, linkage, bearings, steering head bearings

Suspension Front:

Front fork service (oil change, seal replacement, spring inspection, damping adjustments)

Suspension Rear:

Rear shock absorber service, linkage maintenance, spring adjustments

Brakes Front:

Brake caliper service, master cylinder, brake pads, brake disc inspection and replacement, bleeding procedure

Brakes Rear:

Brake drum or disc service, brake shoe/pad replacement, master cylinder, bleeding procedure

Wheels And Tires:

Wheel bearing inspection, spoke tension, tire pressure specifications, rim maintenance

Electrical System:

Wiring diagrams, battery service, lighting system (headlight, taillight, turn signals), charging system (stator, rectifier/regulator), starter motor, switches

Bodywork And Plastics:

Fairing removal and installation, seat, tank, fenders, general body panel maintenance

Controls:

Throttle cable, clutch cable, brake levers, shifter linkage adjustment

Procedures Included

Preventative Maintenance:

Scheduled maintenance, lubrication points, filter replacement intervals

Troubleshooting:

Diagnostic charts for common problems (e.g., starting issues, engine misfires, electrical faults)

Repair:

Step-by-step repair instructions for all major components and systems

Disassembly And Reassembly:

Detailed instructions for component removal and installation

Specifications And Measurements:

Torque specifications, engine tolerances, electrical resistance values, fluid levels

Technical Depth

Depth:

Comprehensive (suitable for professional mechanics and advanced DIY enthusiasts)

Diagnostic Capabilities:

Advanced troubleshooting and diagnostic procedures

📊 Manual Specifications

File Format

Digital Format:

Typically PDF, often with searchable text and high-resolution diagrams

Print Quality

Diagram Clarity:

High-quality, clear, and detailed exploded diagrams and schematics

Binding Type

Physical Binding:

If printed: Spiral-bound or perfect-bound for lay-flat usability

Paper Type

Physical Paper:

If printed: Durable, glossy paper to withstand workshop conditions

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, single-cylinder

Displacement:

249 cc

Bore X Stroke:

73.0 mm x 59.5 mm

Cooling System:

Liquid-cooled

Performance

Horsepower Est:

Approximately 26-30 hp (Varies by market and tuning)

Torque Est:

Approximately 20-23 Nm (Varies by market and tuning)

Fuel System

Carburetion:

Single Mikuni VM28SS or similar (specific model dependent)

Fuel Type:

Unleaded gasoline (91-98 RON recommended)

Ignition System

Ignition:

Digital CDI

Lubrication System

Oil Capacity Est:

1.6 - 1.8 Liters (check manual for exact spec)

Oil Type Recommendation:

SAE 10W-40 API SG or higher (check manual for exact spec)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Transmission Options:

N/A (Standard 6-speed)

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length Est:

2190 mm

Width Est:

805 mm

Height Est:

1230 mm

Wheelbase Est:

1430 mm

Weights

Dry Weight Est:

118 kg

Wet Weight Est:

128 kg (approx. with fluids)

Suspension Travel

Front Suspension Travel:

270 mm (approx.)

Rear Suspension Travel:

255 mm (approx.)

Tire Sizes

Front Tire:

80/100-21 46P

Rear Tire:

110/100-18 64P

Fuel Capacity

Fuel Tank Capacity:

10 Liters (approx.)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is typically assessed by rider skill and adherence to regulations)

Active Features

Braking System:

Disc front, Drum rear (or Disc rear on some variants)

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals (DOT/ECE compliant depending on market)

💡 Technology Features

Infotainment

Infotainment Features:

Basic analogue instrumentation (speedometer, tachometer, odometer, indicator lights). No modern infotainment features.

Driver Assistance

Driver Assistance Systems:

None. Rider skill and attentive riding are the primary safety systems.

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 3,000-4,000 km or 6 months (refer to manual for exact)

Air Filter Cleaning:

Every 1,000-2,000 km, replace as needed

Spark Plug Inspection:

Every 3,000-5,000 km

Chain Lubrication And Adjustment:

Every 500-1,000 km

Valve Clearance Check:

Every 6,000-8,000 km

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant (50% mixture with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for specific recommendation)

Known Issues

Carburetor Tuning:

Can be sensitive to altitude and temperature changes, requiring periodic adjustment.

Suspension Seals:

Fork seals can wear over time, especially with aggressive off-road use, leading to leaks.

Electrical Connections:

Corrosion or loose connections can cause intermittent electrical issues, especially in humid or off-road conditions.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for performance and innovation.

Model Evolution

Klx Lineage:

The KLX series represents Kawasaki's commitment to off-road and dual-sport motorcycles, evolving over decades to incorporate new technologies and performance improvements.

Production

Manufacturing Location:

Japan (primarily)

Production Period:

The KLX250 line has seen multiple iterations, with the E1 designation specific to the 1993 model year, following earlier versions and preceding later updates.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards for the 1993 KLX250E1 are not widely documented; however, the KLX line has consistently been recognized for its off-road capability and durability in its class.