Segment:
Lightweight dual-sport/off-road motorcycle.
Target Audience:
Enthusiasts seeking versatile trail riding and light street use. Competes with Yamaha WR250, Honda XR250.
Key Competitors:
Yamaha WR250, Honda XR250, Suzuki DR350.
Vehicle Design Philosophy:
Emphasis on off-road capability with street-legal features, relatively simple and robust design.
Manual Value Proposition:
Essential resource for maintaining and repairing the KLX250R, saving costs on professional service, and enabling owners to perform their own maintenance and repairs.
Engine Mechanical:
Engine assembly, disassembly, inspection, repair procedures for cylinder head, cylinder, piston, crankshaft, connecting rod, lubrication system, cooling system.
Fuel System:
Carburetor (Keihin CVK) inspection, cleaning, adjustment, rebuilding, fuel tank, fuel pump, fuel lines.
Ignition System:
CDI ignition system, spark plug specifications, troubleshooting, testing.
Transmission Drivetrain:
Clutch operation, inspection, adjustment, transmission gear inspection and repair, final drive (chain and sprockets).
Cooling System:
Radiator, cooling fan, coolant circulation, thermostat operation, troubleshooting leaks.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system (stator, regulator/rectifier), starter motor, horn, instrumentation.
Suspension:
Front fork (telescopic, cartridge type) disassembly, inspection, seal replacement, oil level and type, rear shock absorber inspection and adjustment, linkage system maintenance.
Brakes:
Front and rear hydraulic disc brake systems, caliper disassembly and inspection, master cylinder servicing, brake pad replacement, brake fluid type and bleeding procedures.
Wheels Tires:
Wheel bearing inspection and repacking, tire pressure recommendations, tire wear analysis, spoke tension (if applicable).
Frame Chassis:
Frame inspection for damage, steering head bearing maintenance, swingarm bearing service.
Bodywork:
Fairing, fenders, seat, fuel tank removal and installation, graphics replacement.
Scheduled Maintenance:
Detailed schedules for oil changes, filter replacements, chain adjustment, valve clearance checks, spark plug replacement, brake inspections.
Troubleshooting:
Diagnostic flowcharts and step-by-step procedures for common starting, running, electrical, and braking issues.
Engine Overhaul:
Complete procedures for engine disassembly, component inspection, measurement, reassembly, and break-in.
Carburetor Tuning:
Step-by-step instructions for cleaning, adjusting idle speed, jetting changes, and troubleshooting fuel delivery issues.
Suspension Rebuild:
Instructions for fork seal replacement, oil changes, and general suspension maintenance.
Electrical Diagnostics:
Guidance on using a multimeter to test components, wiring continuity, and voltage checks.
Brake System Service:
Detailed procedures for bleeding brakes, replacing pads, and servicing calipers.
Torque Specifications:
Precise torque values for all critical fasteners during assembly and disassembly.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic checks to complete engine rebuilds and advanced diagnostics.
Engine Type:
Four-stroke, liquid-cooled, DOHC, single-cylinder.
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 x 61.2 mm (2.83 x 2.41 in.)
Compression Ratio:
10.0:1 (approx.)
Horsepower:
Approx. 28-30 HP @ 7000-7500 RPM (varies slightly by year/market)
Torque:
Approx. 20-22 lb-ft @ 5500-6000 RPM (varies slightly by year/market)
Carburetor:
Keihin CVK34 (Constant Velocity Carburetor)
Fuel Type:
Unleaded gasoline
Oil Type:
API SE, SF, or SG class, SAE 10W-40 motorcycle specific oil recommended. Check manual for specific viscosity based on ambient temperature.
Oil Capacity:
Approx. 1.7 L (1.8 US qt) with filter change, 1.5 L (1.6 US qt) without filter change. Check dipstick.
Ignition Type:
Digital CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR9EK or equivalent (check manual for specific recommendation and gap)
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol based coolant with distilled water (50/50 mixture) recommended. Check manual for specific type.
Length:
Approx. 2,180 mm (85.8 in.)
Width:
Approx. 805 mm (31.7 in.)
Height:
Approx. 1,230 mm (48.4 in.)
Wheelbase:
Approx. 1,425 mm (56.1 in.)
Ground Clearance:
Approx. 305 mm (12.0 in.)
Seat Height:
Approx. 890 mm (35.0 in.)
Dry Weight:
Approx. 116 kg (255.7 lbs)
Curb Weight:
Approx. 127 kg (280 lbs) (with fluids)
Fuel Capacity:
Approx. 11 L (2.9 US gal)
Engine Oil Change:
Every 3,000 km (1,800 mi) or 6 months, whichever comes first. More frequently under severe use.
Oil Filter Replacement:
With every oil change.
Chain Lubrication Adjustment:
Every 500-1000 km (300-600 mi) or as needed. Check tension.
Air Filter Cleaning:
Every 1,000-2,000 km (600-1,200 mi) or more often in dusty conditions. Service as per manual.
Valve Clearance Check:
Every 6,000 km (3,700 mi) or 12 months. Crucial for engine performance and longevity.
Spark Plug Replacement:
Every 6,000 km (3,700 mi) or as needed based on inspection. Check gap.
Brake Fluid Change:
Every 2 years or as recommended by manual. Inspect pads and discs regularly.
Engine Oil Spec:
SAE 10W-40, API SE/SF/SG or equivalent motorcycle oil.
Coolant Spec:
50/50 mix of ethylene glycol coolant and distilled water.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid.
Carburetor Stalling:
Can be prone to clogging if fuel is left to sit, or if air filter is neglected. Regular cleaning and proper fuel stabilizer use is key.
Suspension Leaks:
Fork seals and rear shock bushings can wear over time, leading to leaks. Regular inspection and maintenance are recommended.
Valve Tightening:
Valve clearances can tighten over time, leading to loss of power and hard starting. Adhering to the valve adjustment schedule is vital.
Cam Chain Noise:
Some models may develop a slight cam chain rattle if not properly tensioned or if the tensioner is worn. The manual will detail inspection and replacement of the cam chain tensioner.
