Segment:
Lightweight Dual-Sport/Enduro Motorcycle
Target Audience:
Enthusiasts, off-road riders, dual-sport adventurers, mechanics
Competitors:
Yamaha WR250, Honda CR250L, Suzuki DR250S
Vehicle Attributes:
Lightweight, agile, reliable, off-road capable with street legality
Manual Value Proposition:
Enables DIY maintenance and repair, crucial for preserving performance and longevity of a classic dual-sport.
Primary Coverage:
Complete Workshop Manual
Scope:
Maintenance, Repair, Troubleshooting, Overhaul
Estimated Pages:
~300-400 (typical for comprehensive manuals of this era)
Type:
Service Manual / Repair Manual
Format:
Digital (PDF/eBook) or Printed
Engine:
Top-end rebuild, bottom-end overhaul, valve adjustment, carburetor tuning, cooling system, lubrication system
Transmission:
Clutch assembly, gear shifting mechanism, transmission gear inspection and replacement, shift drum and forks
Chassis Suspension:
Front fork (oil change, seal replacement, damping adjustment), rear shock absorber (rebuild, spring adjustment), swingarm and linkage lubrication/inspection
Brakes:
Front and rear brake system (pad replacement, caliper service, master cylinder overhaul, fluid bleeding), disc inspection
Electrical System:
Ignition system (CDI, spark plug, coil), lighting, starter motor, battery, charging system (stator, rectifier/regulator), wiring diagrams
Fuel System:
Carburetor (disassembly, cleaning, jetting, float adjustment), fuel tank, fuel lines, petcock
Cooling System:
Radiator, hoses, thermostat, coolant specifications
Exhaust System:
Muffler, header pipe inspection and replacement
Routine Maintenance:
Oil change, filter replacement, air filter cleaning, chain adjustment and lubrication, spark plug check/replacement, brake fluid check
Troubleshooting:
Diagnostic flowcharts for common starting, running, and electrical issues
Engine Rebuild:
Step-by-step instructions for complete engine disassembly and reassembly
Suspension Overhaul:
Detailed guidance on fork and shock absorber servicing
Electrical Diagnostics:
Use of wiring diagrams, component testing procedures
Carburetor Rebuilding:
Complete guide to carb disassembly, cleaning, and reassembly with specific jet sizes
Depth:
Comprehensive (from basic maintenance to full engine and chassis rebuilds)
Diagnostic Level:
Advanced (includes fault finding trees and component testing)
Diagrams Illustrations:
Detailed exploded views, schematics, and step-by-step photos/illustrations
Digital Format:
PDF (Portable Document Format)
Searchable Text:
Yes (if digitized from original OCR-enabled source)
Digital Quality:
High-resolution scans for clarity of text and diagrams
Printed Binding:
Spiral-bound or perfect-bound (for ease of use in workshop environments)
Printed Paper:
Durable, grease-resistant paper (typical for workshop manuals)
Engine Type:
Four-stroke, single-cylinder, DOHC
Displacement:
249 cc (15.2 cubic inches)
Bore X Stroke:
74.0 mm x 58.0 mm (2.91 in x 2.28 in)
Cooling System:
Liquid-cooled
Horsepower Estimated:
~28 hp @ 8500 rpm (varied slightly by market/tune)
Torque Estimated:
~2.4 kgf⋅m (17.4 lb⋅ft) @ 7000 rpm
Carburetor Type:
Mikuni VM34SS (single, constant velocity)
Fuel Capacity:
10.0 L (2.6 US gal)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Safety Certification:
Not applicable for off-road motorcycles of this era in the same way as cars.
Braking System:
Hydraulic disc brakes front and rear
Lighting:
Headlight, taillight, brake light, turn signals (street-legal models)
Frame Type:
High-tensile steel semi-double cradle frame
Dashboard Features:
Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators, coolant temperature warning light.
Rider Aids:
None (basic mechanical controls)
Connectivity Features:
None (pre-internet era motorcycle)
Engine Oil Change:
Every 3,000 km (1,800 mi) or 6 months
Oil Filter Replacement:
Every 6,000 km (3,600 mi) or 12 months
Air Filter Cleaning:
Every 1,000 km (600 mi) or as needed based on riding conditions
Valve Clearance Check:
Every 6,000 km (3,600 mi)
Chain Lubrication:
Every 500 km (300 mi) or after riding in wet conditions
Engine Oil Type:
SAE 10W-40 API SG or higher motorcycle-specific oil
Engine Oil Capacity:
1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change
Coolant Type:
Permanent type antifreeze (ethylene glycol based) with demineralized water (50:50 mix)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Carburetor Issues:
Potential for clogged jets due to fuel quality or sitting for extended periods. Requires regular cleaning and adjustment.
Suspension Wear:
Fork seals and bushings can wear over time, leading to leaks and reduced damping performance. Rear shock absorber may lose damping.
Cam Chain Tensioner:
Some models may experience cam chain rattle if the automatic tensioner fails or the chain stretches. Manual replacement is an option.
Electrical Connector Corrosion:
Connectors in exposed areas can corrode, leading to intermittent electrical issues. Inspection and cleaning are recommended.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine division
Klx Lineage:
The KLX lineage is known for its versatility in off-road and dual-sport applications, evolving from earlier KDX and KX models.
Klx250R Positioning:
The KLX250R (R for Racing) was positioned as a more competition-oriented dual-sport than its KLR sibling, focusing on off-road prowess.
Production Period:
The KLX250R was produced in various iterations, with the 'R' designation often referring to the more off-road focused models. This generation (1993-1996) represents a significant phase.
