Model:
KLX250/KLX300/KLX250R/KLX300R
Model Designations:
KLX250, KLX300, KLX250R, KLX300R
Vehicle Type:
Dual-Sport Motorcycle
First Generation Years:
1993-1996 (KLX250R/KLX300R), 1994-1996 (KLX250/KLX300 - primarily for Japanese domestic market, though variants existed)
Second Generation Years:
1997-2007 (KLX250/KLX250R, significant updates and expansion)
Chassis Code Examples:
KL250-D1 (for early models), KLX250-D2, KLX250-E1 (potentially for later variants/updates within the 1993-1997 range)
Engine Code Examples:
KL250AE (for 250cc), KLX300AE (for 300cc - approximate, specific designations vary)
Segment:
Lightweight dual-sport/off-road motorcycle, popular for trail riding, commuting, and light adventure touring.
Target Audience:
Enthusiasts and owners seeking to perform their own maintenance and repairs, or to understand the technical aspects of their motorcycle.
Competitors Early 90S:
Honda XR250L, Yamaha XT250, Suzuki DR250S.
Key Selling Points:
Reliable liquid-cooled engine, capable suspension, relatively lightweight for its class, strong aftermarket support.
Engine Type:
Liquid-cooled, four-stroke, single-cylinder DOHC.
Suspension:
Long-travel telescopic front forks, Uni-Trak rear suspension (specifics vary by R models).
Braking:
Disc brakes front and rear.
Design Philosophy:
Off-road performance blended with road legality for versatility.
Covered Models:
Kawasaki KLX250, KLX300, KLX250R, KLX300R
Covered Years:
1993, 1994, 1995, 1996, 1997
Manual Type:
Service Repair Manual
Manual Orientation:
Diagnostic, Repair, Maintenance
Format:
Downloadable File (likely PDF)
Engine Mechanical:
Engine overhaul, cylinder head, piston, crankshaft, lubrication system, cooling system, engine tuning.
Fuel System:
Carburetor (likely Keihin CVK type) disassembly, cleaning, adjustment, fuel pump, fuel lines.
Ignition System:
CDI unit, ignition timing, spark plug specifications, stator, ignition coil.
Transmission:
Clutch operation, gear shifting mechanism, gearbox disassembly, inspection, repair, oil specifications.
Chassis Frame:
Frame inspection, swingarm, steering head bearings, rear shock absorber, front forks (suspension tuning and service).
Braking System:
Front and rear disc brake systems, hydraulic lines, caliper service, master cylinder, brake fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system (alternator/stator), starter motor, fuses, relays, switches.
Wheels Tires:
Wheel bearing service, spoke tensioning (if applicable), tire pressure recommendations, wheel balancing.
Exhaust System:
Exhaust pipe inspection, muffler service, emissions controls (if applicable).
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, decals.
Preventative Maintenance:
Oil change intervals, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic charts for common starting issues, engine performance problems, electrical faults.
Engine Repair:
Complete engine disassembly, inspection of internal components (valves, rings, bearings), reassembly with torque specifications.
Suspension Service:
Fork seal replacement, fork oil changes, rear shock absorber service.
Carburetor Tuning:
Idle speed adjustment, mixture screw settings, jetting recommendations (for altitude/modifications).
Electrical Diagnostics:
Use of multimeters to test circuits, component testing (coils, regulators, stators).
Brake System Overhaul:
Piston seal replacement, bleed screw service, master cylinder rebuild.
Depth:
Comprehensive from basic maintenance to complete engine and chassis rebuilds. Includes detailed exploded views and specifications.
Diagnostic Level:
Advanced troubleshooting guides and symptom-based diagnostic procedures.
Rebuild Instructions:
Step-by-step instructions for major component overhauls, including torque values and clearances.
Engine Type:
Liquid-cooled, four-stroke, DOHC, 4 valves per cylinder, single-cylinder
Displacement 250:
249 cc (approx.)
Displacement 300:
292 cc (approx.)
Horsepower 250 Est:
Approx. 26-30 HP (depending on tune and market)
Torque 250 Est:
Approx. 18-20 lb-ft (depending on tune and market)
Horsepower 300 Est:
Approx. 30-34 HP (depending on tune and market)
Torque 300 Est:
Approx. 20-23 lb-ft (depending on tune and market)
Carburetor Type:
Keihin CVK34 (common for this era), some models may have different sizes or carburetor types.
Fuel Delivery:
Carburetor
Safety Ratings:
N/A (Motorcycles are not typically rated by organizations like NHTSA or IIHS)
Braking Type:
Front and rear disc brakes.
Suspension Design:
Long travel suspension aids in maintaining tire contact over uneven terrain, improving control.
Lighting:
Headlight, taillight, brake lights, turn signals (compliance varies by market).
Ergonomics:
Designed for rider comfort and control during off-road excursions and on-road riding.
Oil Change Interval:
Typically every 3,000-5,000 km or 6 months, refer to manual for exact specification.
Spark Plug Replacement:
Recommended at 12,000-15,000 km or as per manual. Check gap regularly.
Air Filter Service:
Clean or replace every 6,000-10,000 km, or more frequently in dusty conditions.
Engine Oil Type:
API SG or higher, SAE 10W-40 motorcycle-specific oil is common. Consult manual for exact viscosity and API rating.
Engine Oil Capacity:
Approx. 1.7 - 1.9 Liters (with filter change). Consult manual for exact capacity.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (typically 50/50). Refer to manual for specific concentration and type.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Always use fresh fluid.
Transmission Oil Type:
Often shares engine oil, but manual will specify if separate or specific requirements.
Carburetor Fouling:
Can experience gumming or clogging if fuel sits for extended periods. Regular use or stabilizer advised.
Cooling System Leaks:
Hose connections or radiator leaks can occur with age. Regular inspection of hoses and coolant levels is important.
Suspension Wear:
Fork seals and bushings can wear over time, leading to leaks or a harsh ride. Regular fork oil changes and seal checks are recommended.
Cam Chain Tensioner:
Some older single-cylinder engines can develop cam chain noise if the tensioner is worn. The manual will detail inspection and replacement.
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries has a long-standing reputation for performance and reliability in motorcycles, including off-road and dual-sport segments.
Klx Lineage:
The KLX line has been a staple for Kawasaki in the off-road and dual-sport categories, evolving from the KLR and KX lines.
Klx250R Klx300R Focus:
These models represented a step up in performance from earlier dual-sport offerings, with the 'R' designation often implying a more off-road biased design or performance tuning.
Manufacturing Location:
Primarily Japan. Specific assembly locations may vary by market.
Market Introduction:
The KLX250R and KLX300R were introduced to cater to the growing demand for capable dual-sport machines.
