Positioning:
The KLX250R was positioned as a capable and versatile dual-sport motorcycle, appealing to riders seeking off-road prowess with street legality.
Target Audience:
Enthusiasts looking for adventure riding, trail exploration, and commuting.
Competitors:
Competed with models like the Yamaha XT250, Honda XR250L, and Suzuki DR250S of its era.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, single-cylinder engine.
Suspension Type:
Adjustable front forks and Uni-Trak rear suspension for enhanced off-road capability.
Braking System:
Disc brakes front and rear for reliable stopping power.
Manual Value Proposition:
This manual is essential for owners and technicians to maintain, diagnose, and repair the KLX250R, ensuring its longevity and optimal performance.
General Coverage:
Comprehensive service and repair procedures for the Kawasaki KLX250R motorcycle.
Specific Systems:
Engine, Fuel System, Ignition System, Transmission, Drivetrain, Suspension, Brakes, Electrical System, Chassis, Bodywork, Troubleshooting, Maintenance.
Type:
Factory Service Manual (FSM)
Engine:
Detailed information on disassembly, inspection, assembly, tuning, and troubleshooting of the 249cc 4-stroke engine.
Fuel System:
Carburetor (Keihin CVK34) overhaul, adjustment, and troubleshooting, including jetting specifications.
Ignition System:
CDI ignition system diagnostics, timing, and component testing.
Transmission Drivetrain:
Clutch operation, gearbox disassembly, inspection, and lubrication; chain and sprocket maintenance.
Suspension:
Front fork (conventional telescopic) and rear monoshock (Uni-Trak) disassembly, inspection, service, and damping adjustments.
Brakes:
Front and rear disc brake system maintenance, caliper overhaul, pad replacement, bleeding procedures, and fluid specifications.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, starter system, charging system (stator, regulator/rectifier) diagnostics.
Chassis Bodywork:
Frame inspection, steering head bearing service, wheel and tire maintenance, body panel removal and installation.
Routine Maintenance:
Oil changes, filter replacement, air filter cleaning, spark plug service, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic charts and flowcharts for common starting, running, and electrical issues.
Engine Rebuild:
Complete engine disassembly, cylinder head service, piston and ring replacement, crankshaft and connecting rod inspection/repair.
Suspension Service:
Fork seal replacement, fork oil change and level adjustment, rear shock absorber servicing.
Brake Overhaul:
Master cylinder rebuilding, caliper seal replacement, brake line inspection and replacement.
Electrical Diagnostics:
Testing components like CDI unit, ignition coil, stator, rectifier, and troubleshooting wiring harness issues.
Depth:
Expert level, covering everything from basic adjustments to complete engine and suspension overhauls.
Diagnostic Tools:
Includes specifications for using standard mechanic's tools and diagnostic equipment.
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single cylinder
Displacement:
249 cc (250cc class)
Bore X Stroke:
72.0 mm x 61.2 mm (approx.)
Compression Ratio:
9.3:1 (typical for the era)
Power Output:
Approx. 28-30 HP at 7,500 RPM (typical, may vary by market)
Torque:
Approx. 20-22 lb-ft at 6,000 RPM (typical, may vary by market)
Cooling System:
Liquid-cooled with radiator and fan.
Carburetor Type:
Keihin CVK34 with DFI (Digital Fuel Injection) on some later models, though manual primarily covers carb version.
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 2.6 gallons (10 Liters)
Oil Change Interval:
Every 2,000 km or 6 months (check manual for exact details).
Air Filter Cleaning:
Every 1,000 km or as needed depending on conditions.
Spark Plug Service:
Every 6,000 km.
Valve Clearance Check:
Every 12,000 km.
Engine Oil Type:
SAE 10W-40 API SG or higher (check manual for precise specification).
Engine Oil Capacity:
Approx. 1.7 Liters with filter change.
Coolant Type:
Permanent type anti-freeze (ethylene glycol based) with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, and carburetor diaphragm can be wear items requiring periodic replacement.
Potential Electrical Issues:
Age-related degradation of wiring insulation or regulator/rectifier failure can occur, which this manual helps diagnose.
Carburetor Tuning:
Proper carburetor tuning is crucial for optimal performance; this manual provides detailed procedures and specifications.
Kawasaki Legacy:
Kawasaki Heavy Industries has a long and storied history in motorcycle manufacturing, known for performance and innovation in various segments, including off-road and dual-sport.
Klx Lineage:
The KLX line has evolved significantly over the years, with the KLX250R representing a key iteration in the 250cc dual-sport category, offering a blend of ruggedness and usability.
Klx250R Production Period:
Produced through the 1990s, with this manual covering the specific generation from 1993 to 1997.
