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Kawasaki KLX 250 Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 Product Type: Service Repair Manual Product Name: Kawasaki KLX250 Service Repair Manual 👋 Introduction Market Position Segment: Dual-Sport / Off-Road Target Audience:...
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🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250
Product Type:
Service Repair Manual
Product Name:
Kawasaki KLX250 Service Repair Manual
👋 Introduction
Market Position
Segment:
Dual-Sport / Off-Road
Target Audience:
Enthusiasts, commuters, adventure riders
Competitive Analysis
Competitors:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250
Key Features
Versatility:
Capable on pavement and off-road trails
Reliability:
Known for its robust engine and chassis
Performance:
Balanced power delivery for various riding conditions
📋 Manual Details
Coverage Areas
Engine Overhaul:
Comprehensive
Electrical System:
Complete
Suspension System:
Detailed
Brake System:
In-depth
Chassis Frame:
Full Coverage
Fuel System:
Thorough
Cooling System:
Comprehensive
Exhaust System:
Detailed
Wheels Tires:
Complete
Bodywork Plastics:
Detailed
Troubleshooting:
Extensive diagnostics
Page Count
Estimated Pages:
Approximately 400+
Manual Type
Type:
Factory Service Manual
Subtype:
Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete disassembly, assembly, tuning, and troubleshooting
Transmission:
Clutch, gearbox, lubrication, and troubleshooting
Fuel System Efi Carb:
EFI system diagnostics and components (if applicable to model variant), carburetor overhaul and adjustment
Ignition System:
CDI, spark plugs, timing, and troubleshooting
Cooling System Liquid:
Radiator, hoses, thermostat, water pump, and coolant specifications
Exhaust System Emissions:
Muffler, catalytic converter (if equipped), emissions controls
Electrical System Charging:
Stator, alternator, battery, charging system testing
Electrical System Lighting:
Headlight, taillight, brake lights, turn signals, wiring diagrams
Electrical System Ignition Start:
Starter motor, starter solenoid, ignition switch
Brakes Front:
Caliper, disc, pads, master cylinder, fluid specifications, bleeding procedures
Brakes Rear:
Caliper, disc, pads, master cylinder, fluid specifications, bleeding procedures (drum brake details if applicable)
Suspension Front Forks:
Disassembly, assembly, oil type, oil level, seals, springs
Suspension Rear Shock:
Shock absorber overhaul, adjustments, linkage maintenance
Steering System:
Handlebars, triple clamps, steering stem bearings, adjustment
Wheels Hubs Spokes:
Wheel bearing replacement, spoke tensioning, hub maintenance
Chassis Frame Structure:
Frame inspection, welding points, frame integrity checks
Body Panels Fairings:
Removal, installation, and care of plastic components
Wiring Diagrams:
Detailed electrical schematics for all systems
Procedures Included
Preventive Maintenance:
Scheduled service intervals, inspections, lubrication points
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, tire pressure checks
Engine Rebuild:
Step-by-step instructions for complete engine overhauls
Transmission Repair:
Gearbox disassembly, inspection, and reassembly
Suspension Fork Rebuild:
Seal replacement, fluid changes, valving inspection
Brake System Service:
Pad replacement, fluid flush and bleed, caliper service
Electrical Troubleshooting:
Diagnostic procedures for common electrical faults
Carburetor Tuning:
Adjustment procedures for optimal performance and fuel economy
Fuel Injection Diagnostics:
Troubleshooting fuel delivery and sensor issues (if applicable)
Cooling System Flushing:
Procedure for draining, flushing, and refilling coolant
Wheel Bearing Replacement:
Step-by-step guide for replacing wheel bearings
Tire Mounting Balancing:
Guidelines for tire installation and balancing
Technical Depth
Depth:
Expert Level
Diagnostic Capabilities:
Provides detailed diagnostic trees and fault code explanations
Rebuild Procedures:
Covers complete component rebuilds with torque specifications and clearances
Specifications Tolerances:
Includes all necessary technical specifications, measurements, and tolerances
📊 Manual Specifications
File Format
Format:
PDF
Searchable Text:
Yes
Image Resolution:
High-resolution, clear diagrams and photos
Printable:
Yes
Print Quality
Quality:
N/A (Digital)
Binding Type
Type:
N/A (Digital)
Paper Type
Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Type:
Liquid-cooled, four-stroke, DOHC, single cylinder
Displacement:
249 cc (approximately)
Bore X Stroke:
72.0 x 61.2 mm (example, varies by year)
Compression Ratio:
11.0:1 (example, varies by year)
Performance
Horsepower:
Approx. 30-34 HP (varies by year and market)
Torque:
Approx. 20-22 Nm (varies by year and market)
Fuel System
Fuel Delivery:
Fuel Injection (EFI) or Carburetor (depending on model year and region)
Fuel Type:
Unleaded gasoline
Lubrication
Oil Type:
API SG, SF or SH with JASO MA (refer to manual for exact spec)
Oil Capacity Wfilter:
Approx. 1.5 - 1.7 Liters (check manual)
🔧 Transmission
Standard
Type:
Constant mesh, 6-speed
Features
Clutch Type:
Wet, multi-disc
Final Drive:
Sealed chain
Fluid Specifications
Transmission Oil Type:
API GL-4 SAE 80W-90 gear oil (refer to manual)
📐 Dimensions
Exterior
Length:
Approx. 2,200 - 2,250 mm (varies by year)
Width:
Approx. 810 - 850 mm (varies by year)
Height:
Approx. 1,200 - 1,260 mm (varies by year)
Wheelbase:
Approx. 1,430 - 1,440 mm (varies by year)
Ground Clearance:
Approx. 255 - 300 mm (varies by year)
Seat Height:
Approx. 865 - 880 mm (varies by year)
Weights
Dry Weight:
Approx. 130 - 140 kg (varies by year)
Curb Weight:
Approx. 138 - 148 kg (varies by year)
Fuel Tank Capacity:
Approx. 7.7 - 11 Liters (varies by year)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle)
Active Features
Brakes ABS:
Optional ABS on some models/years
Lighting:
Halogen headlight, LED taillight/brake light (model dependent)
Passive Features
Frame Construction:
High-tensile steel perimeter frame
💡 Technology Features
Infotainment
Display:
Digital LCD instrument cluster
Features Display:
Speedometer, tachometer, fuel gauge, clock, trip meters, indicator lights
Driver Assistance
ABS Availability:
Optional on select models and markets
Connectivity
Connectivity:
N/A (Basic motorcycle)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or 6 months (refer to manual for exact)
Air Filter Cleaning:
Every 6,000 km or 6 months
Spark Plug Replacement:
Every 12,000 km or 12 months
Valve Clearance Check:
Every 12,000 km or 12 months
Chain Lubrication Adjustment:
Every 1,000 km or after washing/rain
Fluid Specifications
Engine Oil Viscosity:
10W-40 (preferred, check manual for variations)
Coolant Type:
Ethylene glycol based, permanent type coolant (50/50 mix)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals
Potential Faults:
EFI sensor issues (less common), stator failures (rare)
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Heritage:
Long history of dirt bikes and dual-sport motorcycles
Model Evolution
Introduction Year:
Original KLX250R introduced in 1993, KLX250S dual-sport variant in 2006
Significant Updates:
Transition from carburetor to fuel injection (2009 model year in many markets), styling updates, engine tuning revisions
Production
Manufacturing Locations:
Japan
Production Status:
Continuous production with model year updates
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Consistently a popular choice in its class for versatility and value
Ratings
Durability Ratings:
High user ratings for long-term reliability