🏷️ Basic Information

Make:

Kawasaki

Model:

KLR250

Product Name:

Kawasaki KLR250 Models- 1984-2005 Complete Repair Manual

Product Description:

Kawasaki KLR250 1984-2005 Complete Repair & Service Manual

Chassis Codes:

KL250-A1 to KL250-D25 (varies by year and sub-model)

👋 Introduction

Segment:

Dual-sport motorcycle, popular for its versatility in on-road and off-road riding.

Competitors:

Honda XR250L, Yamaha XT250, Suzuki DR250SE.

Dual Sport Capability:

Designed for both paved roads and light off-road trails.

Durability:

Known for its rugged construction and reliability over a long production run.

Liquid Cooling:

Many later models feature liquid cooling for improved performance and longevity.

📋 Manual Details

Covered Years:

1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Estimated Page Count:

Approx. 400-600 pages (typical for a complete repair manual of this scope)

Type:

Complete Repair and Service Manual

Language:

English

Format:

Digital (PDF) likely, potentially printed version available

📖 Manual Coverage

Engine:

Engine overhaul, disassembly, assembly, tuning, troubleshooting, carburetor, cooling system (liquid-cooled variants), lubrication.

Transmission:

Gearbox maintenance, clutch service, shift mechanism, lubrication, troubleshooting.

Chassis:

Frame inspection, suspension (front forks, rear shock), steering, wheels, tires, bearings.

Brakes:

Front and rear brake system service (hydraulic disc front, drum rear on some early models, later disc front and rear), fluid replacement, caliper/master cylinder overhaul, bleeding procedures.

Electrical:

Wiring diagrams, ignition system, lighting, battery, charging system (stator, regulator/rectifier), starter motor, fuses, switches, troubleshooting.

Fuel System:

Fuel tank, fuel pump (if applicable), carburetor tuning and overhaul, fuel lines, filters.

Exhaust System:

Muffler and exhaust pipe inspection and replacement.

Bodywork:

Fairings, body panels, seat, fuel tank, fenders, decals, removal and installation.

Maintenance:

Regular servicing, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon problems.

Repair:

Detailed instructions for component repair and replacement.

Rebuild:

Engine and transmission rebuild procedures with torque specifications and clearances.

Adjustment:

Carburetor synchronization, throttle cable adjustment, clutch adjustment, suspension setup.

Depth:

Comprehensive, covering everything from basic pre-ride checks to full engine disassembly and rebuild.

📊 Manual Specifications

Searchable Text:

Likely searchable if PDF format, allowing for quick information retrieval.

Print Quality:

High resolution for clear diagrams and text (assuming digital reproduction quality).

Binding Type:

N/A (for digital), typically comb-bound or perfect-bound for printed versions.

Paper Type:

N/A (for digital), typically heavy-duty paper for printed workshop manuals.

⚙️ Engine Specifications

Engine Type:

Four-stroke, DOHC, 4-valve, Single-cylinder

Displacement:

249 cc (249cc)

Bore X Stroke:

Approximately 72.0 mm x 61.2 mm (varies slightly by revision)

Compression Ratio:

Around 10.0:1 to 11.0:1 (varies by model year/carburetion)

Horsepower:

Estimated 25-30 HP (at crankshaft, varies by year and market)

Torque:

Estimated 17-20 lb-ft (at crankshaft, varies by year and market)

Carburetion:

Mikuni VM Series Carburetor (e.g., VM28SS or similar single carb), later models may have different configurations.

Fuel Type:

Unleaded gasoline, Octane Rating 87 minimum recommended.

Type:

Liquid-cooled (most models after initial release).

Type:

Wet Sump

🔧 Transmission

Type:

6-speed constant mesh

Optional Transmissions:

N/A (standard across all KLR250 models)

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain Drive

📐 Dimensions

Overall Length:

Approximately 86.0 inches (2185 mm)

Overall Width:

Approximately 32.5 inches (825 mm)

Overall Height:

Approximately 47.2 inches (1200 mm)

Wheelbase:

Approximately 56.7 inches (1440 mm)

Ground Clearance:

Approximately 10.2 inches (260 mm)

Dry Weight:

Approximately 277.8 lbs (126 kg)

Curb Weight:

Approximately 304.2 lbs (138 kg)

Fuel Tank Capacity:

Approximately 2.1 US gallons (8.0 Liters)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles are not typically rated by consumer safety organizations like NHTSA for crashworthiness in the same way cars are.)

Brakes:

Disc brakes front and rear (most models), providing good stopping power.

Suspension:

Capable suspension for stability on varied terrain.

Lighting:

Halogen headlight, taillight, and turn signals for visibility.

💡 Technology Features

Infotainment Systems:

N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator).

Driver Assistance Features:

N/A

Connectivity Options:

N/A

🔧 Maintenance

Oil Change:

Every 3,000-4,000 miles or annually (refer to manual for exact interval).

Valve Adjustment:

Every 6,000-8,000 miles (typically).

Chain Lubrication And Adjustment:

Every 500-1,000 miles or after washing/rain.

Engine Oil Type:

API SE, SF, SG or SH classified, SAE 10W-40 motorcycle oil recommended. (Check manual for specific viscosity and API classification based on climate).

Engine Oil Capacity:

Approximately 1.7 US quarts (1.6 Liters) with filter change.

Coolant Type:

Kawasaki All-Weather Coolant or equivalent ethylene glycol-based antifreeze mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (check manual for precise specification).

Carburetor Icing:

Can occur in cold, humid conditions due to the venturi effect; manual will detail potential fixes or carb designs to mitigate this.

Cam Chain Tensioner:

Some owners report the automatic cam chain tensioner can wear, leading to rattling noises; manual will guide on inspection and replacement.

Carb Jetting:

Stock jetting may be lean for some elevations or modifications; manual provides baseline for adjustments.

Charging System:

Potential for regulator/rectifier failure on older units; manual helps diagnose.

📚 Vehicle History

Kawasaki Motorcycles:

Kawasaki Heavy Industries has a long history of producing innovative and reliable motorcycles, particularly in the dual-sport and off-road segments.

Klr250 Development:

The KLR250 was introduced to bridge the gap between smaller dual-sports and larger adventure bikes, offering a balance of capability and manageable size. It evolved through minor updates in styling, suspension, and engine tuning over its production run.

Production Period:

1984-2005

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Industry Recognition:

While specific awards are not widely publicized, the KLR250's enduring popularity and longevity in the market is a testament to its design and utility. It's often lauded as a reliable first dual-sport or an economical adventure touring platform.