Target Audience:
DIY enthusiasts, independent repair shops, and experienced mechanics seeking a definitive resource for the Kawasaki KLR250.
Value Proposition:
Offers a significant cost saving compared to dealership service, provides access to professional-level repair information, and enables self-sufficiency for motorcycle owners.
Documentation Quality:
Features clear, concise text with high-quality diagrams, exploded views, and step-by-step instructions.
Accessibility:
Instant download provides immediate access for on-the-spot repairs, eliminating shipping delays and physical damage concerns.
Engine Systems:
Engine overhaul, top-end components (cylinder, piston, valves), bottom-end components (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable), fuel delivery system (carburetor details), ignition system, exhaust system.
Drivetrain Systems:
Clutch assembly, transmission internal and external components, gear shift mechanism, final drive (chain, sprockets).
Chassis Systems:
Frame, suspension (forks, shock absorber), steering system, wheels, tires, braking system (front and rear), electrical system (wiring diagrams, battery, charging system, lighting, ignition components).
Bodywork And Controls:
Body panels, fuel tank, seat, handlebars, levers, pedals, cables.
Maintenance Procedures:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, brake adjustments, spark plug service, air filter cleaning/replacement, valve clearance adjustment.
Repair Procedures:
Detailed step-by-step instructions for disassembly, inspection, repair, and reassembly of all major vehicle components.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, electrical system diagnostics.
Technical Specifications:
Torque specifications for all fasteners, engine tuning parameters, electrical resistance values, dimensional tolerances.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and schematics.
Print Quality:
High-resolution, suitable for printing full pages. Zoom functionality for detailed inspection of diagrams.
Binding Type:
Digital (PDF), allowing for printing of specific sections or entire manual.
Paper Type:
N/A (Digital Format)
Software Requirements:
Adobe PDF Reader, WinZip or equivalent decompression utility.
Operating Systems:
Compatible with all versions of Windows and Mac OS.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4 valves
Displacement:
249 cc (15.2 cu in)
Bore X Stroke:
70.0 x 64.0 mm (2.76 x 2.52 in)
Compression Ratio:
9.7:1 (varies slightly by year)
Horsepower Estimated:
Approximately 17-20 hp at 7,000-7,500 rpm (varies by year and tuning)
Torque Estimated:
Approximately 14-16 lb-ft at 5,500-6,000 rpm (varies by year and tuning)
Fuel Delivery:
Carbureted (e.g., Keihin CVK34 or similar)
Fuel Type:
Unleaded gasoline
Cooling Method:
Liquid-cooled
Oil Type:
API SG or SH, SAE 10W-40 motorcycle specific oil recommended
Oil Capacity With Filter:
Approximately 1.7 L (1.8 US qt) (refer to manual for exact capacity and filter part numbers)
NHTSA Rating:
N/A (Motorcycle safety ratings are not typically provided by NHTSA in the same way as passenger vehicles).
Braking System:
Front: Single Disc with Hydraulic Caliper. Rear: Drum Brake (some later models may have disc).
Lighting:
Headlight, taillight, brake light, turn signals.
Frame Construction:
High-tensile steel semi-double cradle frame.
Infotainment System:
N/A (Basic motorcycle, no integrated infotainment system).
Rider Assistance:
None (Mechanical control and rider skill are primary factors).
Connectivity Features:
None (Basic motorcycle, no electronic connectivity features).
Dashboard Features:
Analog speedometer, tachometer, odometer, trip meter, engine temperature warning light, neutral indicator, turn signal indicators.
Oil Change Interval:
Every 3,000 km (1,860 miles) or 6 months (whichever comes first), or as specified in the manual.
Air Filter Cleaning:
Every 3,000 km (1,860 miles) or annually, clean and re-oil.
Valve Clearance Check:
Every 6,000 km (3,720 miles) or annually.
Spark Plug Replacement:
Every 6,000 km (3,720 miles) or annually. Check gap at each oil change.
Engine Oil Viscosity:
SAE 10W-40 Motorcycle Oil (API SG or higher)
Coolant Type:
Ethylene glycol based antifreeze solution, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, carburetor jets (due to ethanol in fuel), voltage regulator.
Potential Problems:
Carburetor tuning can be sensitive to altitude and modifications. Some early models may experience charging system issues if not maintained.
Kawasaki Legacy:
Kawasaki has a long history of producing reliable and capable motorcycles, particularly in the dual-sport and off-road segments, building on a reputation for engineering and performance.
Klr250 Introduction:
The KLR250 was introduced in the early 1980s (typically cited as 1984/1985) as a lightweight, versatile dual-sport motorcycle, designed for both on-road commuting and off-road exploration.
Klr250 Updates:
Received updates over its production run, including refinements to the engine, suspension, and styling, but maintained its core dual-sport ethos. Production generally ceased around 2007-2009, making way for the larger KLR650's evolution.
Production Years:
Approximately 1984/1985 to 2007/2009
Manufacturing Location:
Japan
Off Road Capability:
Widely recognized for its robust off-road capability for its class and its ability to handle varied terrain, making it a popular choice for adventure and trail riding.
Reliability Reputation:
Generally holds a good reputation for reliability and durability, especially when properly maintained, which is a key selling point for this model and the utility of the service manual.
