Segment:
Dual-sport / Off-road motorcycle
Competitors:
Yamaha XT250, Honda XR250L
Versatility:
Designed for both on-road and off-road riding, offering a balanced performance
Durability:
Known for its robust construction and reliable performance
For Owners:
Essential resource for maintaining and repairing the 1993 KLX250-E1, ensuring longevity and optimal performance.
For Mechanics:
Provides detailed technical data, diagnostic procedures, and specifications crucial for professional servicing.
Primary Coverage:
Comprehensive service and repair for the 1993 Kawasaki KLX250-E1
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, overhaul procedures, specifications, and wiring diagrams
Estimated Pages:
Approx. 300-400 pages (typical for this era/model)
Type:
Factory Service Manual / Workshop Manual
Engine:
Engine disassembly, assembly, inspection, tuning, cooling system, lubrication system, starting system
Fuel System:
Carburetor removal, cleaning, adjustment, fuel tank, fuel pump, fuel lines
Transmission:
Clutch operation, gearbox disassembly, assembly, inspection, shift mechanism
Drivetrain:
Chain and sprockets, rear hub, swingarm, wheel bearings
Brakes:
Front and rear brake system, hydraulic lines, master cylinders, calipers, brake pads, brake fluid
Suspension:
Front fork disassembly, assembly, oil replacement, seal replacement, rear shock absorber, linkage system
Electrical System:
Ignition system, lighting system, charging system (stator, regulator/rectifier), battery, starter motor, wiring diagrams
Chassis And Bodywork:
Frame inspection, handlebars, footpegs, seat, fenders, body panels, exhaust system
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning
Troubleshooting:
Diagnostic charts, common problems and solutions, electrical troubleshooting guide
Repair:
Step-by-step repair instructions for all major components and systems
Overhaul:
Detailed procedures for engine and transmission rebuilds
Adjustments:
Carburetor tuning, clutch adjustment, suspension setup
Depth:
Comprehensive (from basic maintenance to complete engine rebuilds and electrical diagnostics)
Engine Type:
Four-stroke, DOHC, single-cylinder, liquid-cooled
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 x 61.2 mm (2.83 x 2.41 in.)
Compression Ratio:
11.0:1 (typical, refer to manual for exact spec)
Horsepower:
Approx. 27-30 HP (at crankshaft, dependent on tuning)
Torque:
Approx. 24 Nm (17.7 lb-ft) (at crankshaft, dependent on tuning)
Carburetor:
Keihin CVK34 (Constant Velocity Carburetor)
Fuel Capacity:
12 Liters (3.2 US gal)
Coolant Type:
Ethylene glycol-based coolant, 50/50 mixture with distilled water
Crash Test Results:
Not applicable (Motorcycle)
Brakes:
Disc brakes front and rear for reliable stopping power
Lighting:
Halogen headlight, tail light, brake lights, turn signals for visibility
Engine Oil Change:
Every 3,000 km (1,860 miles) or 6 months
Oil Filter Replacement:
Every 6,000 km (3,720 miles) or 12 months (or with every other oil change)
Air Filter Cleaning:
Every 1,000 km (620 miles) or as needed based on riding conditions
Spark Plug Replacement:
Every 6,000 km (3,720 miles)
Chain Lubrication Adjustment:
Every 500 km (310 miles) or after riding in wet conditions
Engine Oil Grade:
SAE 10W-40 API SG or higher (refer to manual for specific Kawasaki recommendation)
Engine Oil Capacity:
Approx. 1.6 Liters (1.7 US qt) with filter change
Brake Fluid:
DOT 4 (refer to manual for specific recommendation)
Coolant:
50/50 mix of ethylene glycol and distilled water
Carburetor Hang:
Some models may experience slight throttle response lag or 'hang' under certain conditions, often requiring carburetor tuning or cleaning.
Clutch Slippage:
Over time and with heavy use, clutch plates can wear, leading to slippage. Regular inspection and adjustment are recommended.
Fork Seals:
Fork seal leaks can occur with age and mileage, requiring replacement of seals and possibly fork oil.
Electrical Connections:
Corrosion or loose connections in the electrical system can cause intermittent issues, especially in off-road conditions. Manual's wiring diagrams are crucial.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company, Japan
Lineage:
The KLX series has a long history of producing capable dual-sport and off-road motorcycles, evolving from earlier models like the KLR and KDX.
Production Era:
The KLX250 was a popular model in the late 80s and 90s, known for its off-road prowess and versatility as a dual-sport machine.
