🏷️ Basic Information

Make:

Kawasaki

Model:

Klx 250 R

Product Type:

Service & Workshop Repair Manual

👋 Introduction

Segment:

Dual-sport motorcycle

Target Audience:

Off-road enthusiasts, adventure riders, daily commuters seeking versatility.

Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250, KTM 250 EXC-F.

Vehicle Strengths:

Robust construction, tractable engine, capable suspension for off-road use, relatively low seat height compared to some competitors, long-term reliability.

Value Proposition:

Provides essential technical data and procedures to maintain, diagnose, and repair the Kawasaki KLX250R, saving time and money on professional service. Empowers owners with in-depth knowledge.

📋 Manual Details

Primary Coverage:

Mechanical and Electrical Systems

Secondary Coverage:

Maintenance, Troubleshooting, and Repair

Estimated Pages:

300+

Type:

Workshop Service Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Complete engine overhaul, including top-end and bottom-end components, timing, valve adjustments, carburetor/fuel injection system, ignition system.

Transmission:

Clutch, gearbox, shift mechanisms, lubrication, and disassembly/reassembly procedures.

Chassis:

Frame inspection and repair, suspension (forks, rear shock), steering system, wheel bearings, and swingarm.

Brakes:

Hydraulic brake systems (front and rear), caliper maintenance, master cylinder overhaul, pad replacement, fluid bleeding, and disc inspection.

Electrical:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, ignition coil, starter motor, and accessory circuits.

Fuel System:

Fuel tank, petcock, fuel lines, carburetor tuning and cleaning (or fuel injection system diagnosis if applicable to the specific sub-model).

Cooling System:

Radiator, coolant hoses, thermostat, and coolant replacement procedures.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement, and removal/installation.

Maintenance:

Scheduled maintenance (oil changes, filter replacements, chain adjustment, air filter cleaning), general inspection checklists.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.

Repair:

Step-by-step repair instructions for all major components and systems, including disassembly, component replacement, and reassembly.

Overhaul:

Detailed procedures for complete engine, carburetor, and brake system overhauls.

Specifications:

Torque specifications for all fasteners, clearances, fluid capacities, and wear limits.

Depth:

Comprehensive from basic owner maintenance to full engine and chassis rebuilds. Suitable for professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

Format Details:

High-resolution PDF with searchable text for easy navigation and keyword searching. Vector graphics for clear diagrams.

Print Readability:

Designed for clear printing with sharp text and diagrams, suitable for on-the-job use in a workshop environment.

Binding:

Not Applicable (Digital Format)

Paper Quality:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Engine Type:

Four-stroke, DOHC, single-cylinder

Displacement:

249 cc (approx. 15.2 cu in)

Bore X Stroke:

72.0 x 61.2 mm (2.83 x 2.41 in)

Cooling System:

Liquid-cooled

Compression Ratio:

11.0:1 (typical, may vary slightly by year/region)

Horsepower:

Approx. 22-24 hp @ 7,000-8,000 rpm (actual figures vary by year and market regulations)

Torque:

Approx. 15-17 lb-ft @ 6,000-7,000 rpm (actual figures vary by year and market regulations)

Fuel Delivery:

Carburetor (e.g., Keihin CVK34) or Fuel Injection (EFI) depending on model year and market.

Fuel Type:

Unleaded gasoline, 87-octane (91 RON) or higher recommended.

Oil Type:

SAE 10W-40 motorcycle-specific engine oil, JASO MA certified.

Oil Capacity:

Approx. 1.6 - 1.8 Liters (1.7 - 1.9 US qt) with filter change (refer to specific model year manual for exact capacity).

🔧 Transmission

Transmission Type:

6-speed constant mesh

Transmission Options:

N/A (Standard 6-speed)

Clutch Type:

Wet multi-plate, manual

Final Drive:

O-ring sealed chain

Transmission Oil Type:

Dedicated motorcycle gear oil or API GL-4, SAE 80W-90 (refer to manual for specific recommendation).

📐 Dimensions

Length:

Approx. 2,180 mm (85.8 in)

Width:

Approx. 810 mm (31.9 in)

Height:

Approx. 1,190 mm (46.9 in)

Wheelbase:

Approx. 1,425 mm (56.1 in)

Curb Weight:

Approx. 130-135 kg (287-298 lbs) (depending on equipment and region)

Max Load Capacity:

Refer to owner's manual for specific weight limits, typically around 150 kg (330 lbs) for rider and cargo.

Front Tire Size:

80/100-21 M/C 51P

Rear Tire Size:

100/100-18 M/C 59P

Front Suspension Travel:

Approx. 250-270 mm (9.8-10.6 in)

Rear Suspension Travel:

Approx. 230-250 mm (9.1-9.8 in)

🛡️ Safety Features

Crash Test Ratings:

Not applicable for motorcycles in the same way as automobiles.

Braking System:

Disc brakes front and rear. ABS availability varies by market and model year.

Lighting:

Halogen headlight, LED tail light, incandescent turn signals (may vary).

Frame Construction:

High-tensile steel perimeter frame for rigidity and impact absorption.

💡 Technology Features

Infotainment System:

Not applicable (basic motorcycle instrumentation)

Instrumentation:

Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge (on some models), indicator lights (neutral, turn signals, high beam).

ABS:

Available on select later models and markets, typically as an option. Manual coverage will detail ABS system components and diagnostics if equipped.

Connectivity Features:

Not applicable.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,100 miles) or 6-12 months, whichever comes first. Refer to manual for exact interval based on usage.

Air Filter Cleaning:

Every 1,000-2,000 km (600-1,200 miles), or more frequently in dusty conditions.

Spark Plug Replacement:

Every 6,000-10,000 km (3,700-6,200 miles) or as per manual inspection.

Valve Clearance Check:

Every 8,000-12,000 km (5,000-7,500 miles).

Chain Lubrication Adjustment:

Every 500-1,000 km (300-600 miles) and before long rides.

Brake Fluid Type:

DOT 3 or DOT 4 unleaded brake fluid.

Coolant Type:

Permanent type anti-freeze coolant, mixture of 50% coolant and 50% distilled water.

Common Wear Items:

Chain and sprockets, brake pads, tires, air filter, clutch plates (high mileage).

Potential Trouble Spots:

Carburetor jetting sensitivity to altitude and modifications, electrical connectors (corrosion in wet environments), fork seal leaks (off-road abuse).

Specific Model Concerns:

Early carbureted models may require jetting adjustments for optimal performance in varied conditions. Check for recalls related to specific model years (e.g., stator issues on some earlier models).

📚 Vehicle History

Kawasaki Legacy:

Kawasaki Heavy Industries, Ltd. has a long-standing reputation for producing reliable and performance-oriented motorcycles across various genres, including off-road and dual-sport.

Klx Lineage:

The KLX series has been a staple in Kawasaki's off-road and dual-sport lineup for decades, evolving from simpler dirt bikes to more sophisticated dual-purpose machines. The KLX250R itself has seen various iterations, including carbureted and fuel-injected models.

Production Years:

The KLX250R model has been in production in various forms since the early 1990s, with significant updates occurring through the 2000s and later.

Manufacturing Locations:

Primarily manufactured in Japan, though assembly may occur in other regions depending on the specific model year and market.

🏆 Awards & Recognition

Industry Awards:

While specific awards for the KLX250R might be elusive, the KLX lineage is recognized for its durability and versatility in the dual-sport segment, often praised in comparative reviews by motorcycle publications.

Owner Satisfaction:

Generally high owner satisfaction due to its reliability and low running costs for its class. User reviews often highlight its capability in varied terrain.

Emissions Compliance:

Meets EPA and CARB emissions standards for its respective model years. Manual will detail specific procedures for emissions-related components.