Market Segment:
Dual-sport/Off-road motorcycle, popular for trail riding and light street use.
Key Competitors:
Honda XR250L, Yamaha XT250, Suzuki DR250SE.
Klx250 Distinctive Features:
Liquid-cooled 4-stroke engine, disc brakes front and rear, capable off-road suspension, robust build quality for its class.
Target Audience:
Owners, mechanics, and enthusiasts performing maintenance, repair, and restoration on the 1994 Kawasaki KLX250/KLX250R.
Coverage Scope:
Comprehensive repair and service for the 1994 Kawasaki KLX250/KLX250R.
Page Count:
Likely 200-300 pages (typical for a service manual of this era).
Manual Type:
Factory-authorized Service Manual / Repair Manual.
Format:
Digital (PDF likely), potentially printable.
Engine System:
Complete engine overhaul, carburetor tuning and rebuild, ignition system, cooling system, lubrication system, exhaust system.
Transmission System:
Gearbox inspection, maintenance, repair, clutch operation and adjustment, shift mechanism.
Chassis System:
Frame inspection and repair, suspension (front fork and rear shock), steering system, swingarm.
Brake System:
Front and rear brake inspection, hydraulic system, pad replacement, caliper service, master cylinder.
Electrical System:
Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), battery maintenance, ignition coil, starter motor.
Fuel System:
Fuel tank, fuel lines, fuel filter, carburetor (likely Keihin CVK).
Cooling System:
Liquid-cooled engine: radiator, hoses, thermostat, water pump.
Body And Trim:
Fenders, seat, fuel tank cover, side panels, graphics.
Maintenance Procedures:
Oil changes, filter replacement, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustment.
Repair Procedures:
Engine disassembly and reassembly, carburetor cleaning and jetting, piston and cylinder inspection, clutch replacement, fork seal replacement, brake bleeding.
Troubleshooting Guide:
Systematic diagnosis of common problems and their solutions based on symptoms.
Torque Specifications:
Detailed torque values for all critical fasteners across all systems.
Technical Depth:
Comprehensive, covering everything from basic rider maintenance to complete engine and chassis rebuilds, including diagnostics and specifications.
Digital Format:
PDF (Portable Document Format) - typically high resolution for readability and printing.
Print Quality:
Designed for clear printing of text, diagrams, and illustrations.
Binding Type:
Not applicable for digital format; if printed, typically spiral-bound or comb-bound for lay-flat use in a workshop.
Paper Type:
Not applicable for digital format; if printed, usually on durable, semi-gloss paper suitable for workshop environments.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve single cylinder.
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm
Compression Ratio:
11.0:1 (typical for this generation)
Horsepower Rating:
Approximately 28-30 HP @ 7500 RPM (estimated, exact factory spec may vary).
Torque Rating:
Approximately 18-20 lb-ft @ 6000 RPM (estimated).
Carburetor Type:
Keihin CVK34 (Constant Velocity Carburetor)
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
Ignition Type:
CDI (Capacitor Discharge Ignition)
Oil Capacity:
Approx. 1.6 Liters (with filter change)
Recommended Oil Type:
SAE 10W-40 API SG or higher, motorcycle specific.
Transmission Type:
Constant mesh, 6-speed sequential return.
Clutch Type:
Wet, multi-disc, cable-actuated.
Final Drive:
Chain drive.
Transmission Oil Type:
API GL-1 or GL-4 SAE 80W-90 gear oil.
Overall Length:
Approx. 85.0 inches (2160 mm)
Overall Width:
Approx. 32.3 inches (820 mm)
Overall Height:
Approx. 46.7 inches (1185 mm)
Wheelbase:
Approx. 55.7 inches (1415 mm)
Dry Weight:
Approx. 258 lbs (117 kg) - approximate, may vary slightly.
Curb Weight:
Approx. 275-280 lbs (125-127 kg) - with fluids.
Fuel Tank Capacity:
Approx. 2.6 US gallons (9.8 Liters)
Infotainment System:
Basic analog instrumentation: speedometer, odometer, tachometer, engine temperature warning light, neutral indicator. No infotainment system.
Driver Assistance Features:
None. Designed for direct rider input and control.
Connectivity Features:
None. Mechanical and electrical systems only.
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1,000-2,000 km (600-1,200 miles) or as needed based on riding conditions (off-road frequent).
Chain Lubrication Adjustment:
Every 500-1,000 km (300-600 miles) and before long rides.
Valve Clearance Check:
Every 6,000-10,000 km (3,600-6,000 miles).
Engine Oil Spec:
SAE 10W-40 API SG or higher, motorcycle specific.
Coolant Type:
Permanent type anti-freeze coolant, 50/50 mixture with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, carburetor diaphragm.
Electrical Components:
Regulator/rectifier can be a failure point on older units; check stator output.
Carburetor Idling:
Can become finicky with age; requires thorough cleaning and adjustment.
Kawasaki Motorsports Legacy:
Kawasaki has a long history in off-road racing and motorcycle manufacturing, known for performance and reliability.
Klx Lineage:
The KLX line has evolved over decades, with the KLX250 being a staple in the dual-sport category. The 1994 model represents a refined iteration of the air-cooled predecessors, introducing liquid cooling.
Klx250 Production Era:
The KLX250 platform has seen continuous production and updates through the 1990s and into the 21st century, with the 1994 model being part of the early liquid-cooled generation.
