Segment:
Dual-sport / Enduro motorcycle.
Target Audience:
Enthusiasts seeking to maintain, repair, or modify their 1994 Kawasaki KLX250 D2, including off-road riders and commuters.
Competitors 1994:
Honda XR250L, Yamaha XT350, Suzuki DR350.
Off Road Capability:
Long-travel suspension, high ground clearance, knobby tires.
Versatility:
Suitable for both on-road commuting and off-road trail riding.
Engine Design:
Reliable air-cooled four-stroke single-cylinder engine.
Value:
Provides essential technical knowledge for cost-effective ownership and confident maintenance of a vintage dual-sport motorcycle.
Engine:
Top-end, bottom-end, cooling system, lubrication system, intake, exhaust, ignition system.
Fuel System:
Carburetor(s) (type and settings), fuel lines, fuel pump (if applicable).
Transmission:
Clutch, gearbox (internal components, gear ratios), shift mechanism, lubrication.
Drivetrain:
Final drive (chain, sprockets), wheel bearings, swingarm.
Chassis:
Frame, subframe, front suspension (forks, triple clamps), rear suspension (shock absorber, linkage), steering system.
Brakes:
Front disc brake (caliper, master cylinder, rotor, fluid), rear drum brake (components, adjustment), brake lines.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, ignition coils, CDI unit, wiring diagrams.
Wheels And Tires:
Spoke wheel maintenance, tire pressures, wheel balancing, bearing replacement.
Bodywork:
Fairings, seat, fuel tank, fenders, removal and installation procedures.
Maintenance:
Oil changes, filter replacement, spark plug service, air filter cleaning/replacement, chain adjustment, brake pad inspection/replacement, coolant checks, valve clearance checks and adjustments.
Repair:
Engine rebuild (top and bottom end), carburetor overhaul, suspension servicing, brake system bleeding and repair, electrical component diagnosis and replacement, clutch replacement, transmission disassembly and assembly.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding charts, error code interpretations (if applicable).
Technical Data And Specs:
Torque specifications, clearances, fluid capacities, electrical resistance values, timing settings.
Depth:
Comprehensive, covering everything from basic checks to complete engine and transmission rebuilds. Suitable for both amateur mechanics and professional technicians.
Type:
Four-stroke, single-cylinder, DOHC, 4 valves.
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm (Typical for this model, confirm in manual)
Compression Ratio:
9.0:1 (Typical, confirm in manual)
Cooling System:
Air-cooled.
Ignition:
CDI (Capacitor Discharge Ignition).
Horsepower:
Approx. 28-30 HP @ 7500 RPM (Estimate, manual will provide exact figure)
Torque:
Approx. 2.5 kgf-m (24.5 Nm) @ 6000 RPM (Estimate, manual will provide exact figure)
Carburetor:
Keihin CVK32 (Constant Velocity Carburetor) or similar single carburetor setup (confirm exact model in manual).
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Type:
API SE, SF or SG classification, SAE 10W-40 (Manual will specify exact viscosity and API rating).
Capacity:
Approx. 1.7 L (1.8 US qt) with filter change (Confirm in manual).
Length:
Approx. 2200 mm (86.6 in) (Estimate, confirm in manual)
Width:
Approx. 810 mm (31.9 in) (Estimate, confirm in manual)
Height:
Approx. 1220 mm (48.0 in) (Estimate, confirm in manual)
Wheelbase:
Approx. 1430 mm (56.3 in) (Estimate, confirm in manual)
Ground Clearance:
Approx. 285 mm (11.2 in) (Estimate, confirm in manual)
Dry Weight:
Approx. 122 kg (269 lbs) (Estimate, confirm in manual)
Wet Weight:
Approx. 135 kg (297 lbs) (Estimate, confirm in manual)
Front Tire:
80/100-21 M/C 51P (Typical, confirm in manual)
Rear Tire:
100/90-18 M/C 56P (Typical, confirm in manual)
Wheel Type:
Spoked wheels, 21-inch front, 18-inch rear.
Safety Standards:
Conforms to standards applicable for motorcycles of its era and type; no specific crash ratings typically apply to off-road focused motorcycles.
Braking System:
Hydraulic front disc brake, rear drum brake for reliable stopping power.
Suspension:
Long-travel, adjustable front forks and rear monoshock suspension for stability and control over varied terrain.
Frame Construction:
Durable steel frame designed for off-road stresses.
Lighting:
Headlight, taillight, and turn signals for visibility.
Oil Change:
Every 3,000 km (1,860 miles) or 6 months (Manual will provide exact recommendations).
Air Filter Cleaning:
Every 1,000 km (620 miles) or as needed in dusty conditions.
Valve Clearance Check:
Every 6,000 km (3,730 miles) or 12 months (Manual will specify exact interval).
Chain Lubrication And Adjustment:
Every 500 km (310 miles) or as needed.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (Confirm specific recommendation in manual).
Coolant:
Permanent type ethylene glycol based coolant, 50/50 mix with distilled water (Confirm in manual).
Carburetor Performance:
Potential for carburetor jetting issues or wear over time, requiring cleaning and adjustment.
Suspension Seals:
Leaking fork seals or rear shock issues can occur with age and use, requiring replacement.
Cam Chain Tensioner:
Some models of this era may experience cam chain noise, potentially indicating a worn tensioner.
Electrical Connections:
Corroded electrical connectors can lead to intermittent issues, especially in off-road environments.
Heritage:
Kawasaki has a long-standing reputation for producing robust and capable off-road motorcycles, dating back to the early KDX and KLX series.
Klx Lineage:
The KLX250 series has evolved from earlier dual-sport offerings, with the 1994 D2 model representing a refined iteration of this popular platform, known for its balance of performance and reliability.
Production Era:
The KLX250 was produced across various generations, with the 1994 model belonging to a significant iteration before fuel injection became standard in later models.
