Segment:
Dual-sport motorcycle, designed for both on-road and off-road riding.
Target Audience:
Enthusiasts seeking versatile performance for commuting, trail riding, and adventure touring.
Key Competitors 1995:
Honda XR250L, Yamaha XT225, Suzuki DR250SE.
Design Philosophy:
Balance of off-road capability with street-legal amenities, emphasizing reliability and user-friendliness.
Notable Attributes:
Lightweight chassis, tractable engine, capable suspension, and practicality for everyday use.
Primary Coverage:
Complete repair and maintenance for the Kawasaki KLX250-D3 model year 1995.
Secondary Coverage:
Troubleshooting, diagnostics, electrical system schematics, torque specifications, component identification.
Page Count:
Approximately 300 pages (estimated for comprehensive workshop manuals of this era and type).
Manual Type:
Workshop Service Manual
Format:
Printed (Original Factory Publication)
Engine:
Detailed procedures for disassembly, inspection, assembly, and adjustment of the entire engine, including cylinder, piston, crankshaft, camshaft, valve train, lubrication system, and cooling system.
Fuel System:
Carburetor (Mikuni VM28SS) service, adjustment, cleaning, and troubleshooting; fuel tank, petcock, and fuel line maintenance.
Ignition System:
CDI ignition system testing, troubleshooting, component specifications, and timing procedures.
Transmission And Clutch:
Clutch operation, adjustment, and component replacement; transmission gear inspection, lubrication, and troubleshooting; shift mechanism.
Suspension:
Front fork (telescopic) disassembly, oil change, seal replacement, and adjustment; rear shock absorber inspection and service; linkage system maintenance.
Brakes:
Front and rear brake system service, including caliper overhaul, pad replacement, fluid bleeding, and master cylinder inspection.
Electrical System:
Complete wiring diagrams, component testing (lights, horn, starter, battery, charging system), troubleshooting guides, and diagnostic procedures.
Frame And Bodywork:
Frame inspection, steering head bearing service, and body panel removal/installation procedures.
Routine Maintenance:
Oil changes, filter replacement, spark plug inspection/replacement, chain adjustment, air filter cleaning/replacement, brake adjustments, lubrication points.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, including engine performance problems, electrical faults, and operational malfunctions.
Repair And Rebuild:
Detailed, step-by-step instructions for component disassembly, repair, and reassembly, covering major mechanical and electrical systems.
Special Tools:
Identification and usage of specialized tools required for specific maintenance and repair tasks.
Depth Level:
Comprehensive, covering from basic rider maintenance to full engine and transmission rebuilds, including electrical system diagnostics and component-level repairs.
File Format:
Not applicable (Printed Manual)
Print Quality:
Original Factory Specification: High-quality print with clear diagrams and legible text.
Binding Type:
Original Factory Specification: Staple-bound or perfect bound, designed for durability in a workshop environment.
Paper Type:
Original Factory Specification: Durable, often coated paper stock to resist grease and dirt.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4-valve
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.1 mm
Compression Ratio:
11.0:1
Cooling System:
Liquid-cooled
Horsepower Est:
Approximately 25-30 HP (at crank, depending on market tuning)
Torque Est:
Approximately 20-22 Nm (at crank)
Carburetor Model:
Mikuni VM28SS
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
7.7 Liters (2.0 US gal)
Safety Ratings:
Not applicable (Motorcycle, no standardized crash test ratings as for cars).
Braking System:
Front: Hydraulic disc; Rear: Drum brake.
Lighting:
Halogen headlamp, taillight, brake light, turn signals.
Infotainment System:
None (basic analog instrumentation: speedometer, odometer, trip meter, tachometer, neutral indicator, high beam indicator).
Driver Assistance Features:
None (mechanical systems only).
Connectivity Features:
None.
Oil Change Interval:
Every 3,000 km (1,864 miles) or 6 months, whichever comes first.
Air Filter Cleaning Interval:
Every 1,000 km (621 miles) or 3 months, clean and re-oil.
Spark Plug Inspection Interval:
Every 3,000 km (1,864 miles).
Valve Clearance Check Interval:
Every 6,000 km (3,728 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change.
Fork Oil Type:
Showа SS-20W or equivalent (refer to manual for specific viscosity grade).
Fork Oil Quantity:
365 ml (0.38 US qt) per fork leg.
Brake Fluid Type:
DOT 3 or DOT 4.
Common Wear Items:
Clutch plates, brake pads, wheel bearings, steering head bearings, fork seals due to off-road use.
Engine Performance Tips:
Proper carburetor cleaning and jetting are crucial for optimal performance, especially after periods of disuse or changes in altitude/climate.
Electrical Maintenance:
Regular inspection and cleaning of electrical connectors to prevent corrosion and ensure reliable operation.
Kawasaki History:
Kawasaki Heavy Industries, Motorcycle division, has a long-standing reputation for performance and innovation in motorcycles since the 1960s.
Klx Lineage:
The KLX series began as off-road focused machines and evolved to include dual-sport variants like the KLX250, becoming a staple in Kawasaki's lineup.
Klx250 Production Period:
The KLX250 platform has seen continuous production and evolution since the late 1970s/early 1980s, with the D3 designation specifically for the 1995 model.
Motorcycle Awards:
While the KLX250-D3 itself may not have specific widely publicized awards, the KLX lineage is recognized for its durability and versatility in the dual-sport segment by motorcycle publications and riders.
Rider Satisfaction Rating Era:
Generally well-regarded for its balance of performance, reliability, and ease of maintenance during its production run.
