🏷️ Basic Information

Make:

Kawasaki

Model:

KLX250

Year:

1995

Model Code:

E3

Vehicle Type:

Dual-Sport Motorcycle

👋 Introduction

Segment:

The Kawasaki KLX250 was positioned as a capable and versatile dual-sport motorcycle, blending off-road prowess with street legality, appealing to riders seeking adventure on varied terrain.

Competitors:

Competed with other dual-sport motorcycles of its era, such as the Honda XR250L, Yamaha TT-R250, and Suzuki DR250SE, offering a balance of performance, reliability, and off-road capability.

Dual Sport Nature:

Equipped with features for both on-road and off-road use, including dual-purpose tires, lights, mirrors, and suspension suitable for diverse riding conditions.

Engine Type:

Features a proven liquid-cooled, four-valve, DOHC, four-stroke single-cylinder engine known for its reliability and broad powerband.

Suspension Setup:

Equipped with a long-travel telescopic front fork and a Uni-Trak rear suspension system providing excellent ground clearance and bump absorption.

📋 Manual Details

Primary Coverage:

Workshop Repair and Service

Specific Systems:

Engine, Transmission, Chassis, Electrical, Fuel System, Cooling System, Suspension, Brakes, Bodywork, Troubleshooting

Estimated Pages:

300-400

Type:

Factory Service Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Detailed disassembly, assembly, inspection, and overhaul procedures for the 249cc liquid-cooled four-stroke engine. Includes valve clearance adjustment, piston and ring replacement, crankshaft and connecting rod checks, and cylinder head service.

Transmission:

Comprehensive coverage of the 6-speed gearbox, including clutch operation, gear inspection, shift drum and fork removal/installation, and transmission bearing service. Explains gear ratio specifications.

Chassis And Suspension:

Instructions for front fork (telescopic) and rear shock absorber (monoshock) maintenance, including oil changes, seal replacement, and spring preload adjustments. Covers swingarm and linkage bearing service. Includes wheel and hub maintenance.

Brakes:

Detailed procedures for front and rear disc brake systems, including caliper disassembly, pad replacement, brake fluid bleeding, master cylinder service, and hydraulic line inspection. Specifies brake fluid type (DOT 4).

Electrical System:

Wiring diagrams, troubleshooting charts, component testing (ignition system, charging system, lighting), starter motor, battery maintenance, and fuse specifications. Includes CDI unit and stator inspection.

Fuel System:

Carburetor (Keihin CVK) disassembly, cleaning, adjustment, and synchronization. Includes fuel tank, petcock, and fuel line inspection. Covers choke operation and idle speed adjustment.

Cooling System:

Radiator service, coolant replacement, thermostat operation, water pump inspection and seal replacement, and hose inspection. Specifies coolant type (ethylene glycol-based).

Exhaust System:

Muffler and header pipe removal and installation, heat shield inspection, and exhaust gasket replacement.

Bodywork And Trim:

Instructions for removal and installation of fairings, fenders, seat, fuel tank cover, and other body panels. Includes graphics and decal application guidance.

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, tire pressure checks, brake fluid level checks, and battery terminal cleaning.

Troubleshooting:

Systematic diagnostic procedures for common problems related to starting, running, electrical issues, and braking. Includes symptom-based troubleshooting guides.

Component Overhaul:

Complete disassembly and reassembly of major components like the engine, carburetor, forks, and brake calipers.

Specifications And Torques:

Detailed torque specifications for all fasteners, fluid capacities, valve clearances, ignition timing, and other critical engine and chassis settings.

Wiring Diagrams:

Clear and detailed electrical wiring diagrams for all systems, aiding in fault diagnosis and component identification.

Depth:

Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for both home mechanics and professional technicians.

📊 Manual Specifications

Digital Format:

PDF, allowing for easy searching, zooming, and printing of specific sections. Optimized for digital viewing on various devices.

Digital Quality:

High-resolution scans of original factory documentation, ensuring clear text and legible diagrams/illustrations.

Digital Access:

Instant download for immediate use. No physical binding.

Original Print:

Original documentation was printed on durable, high-quality paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Type:

4-stroke, Liquid-cooled, DOHC, 4-valve Single

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

Horsepower:

Approx. 29 hp @ 7,500 rpm (at crankshaft, actual may vary by region/tuning)

Torque:

Approx. 20 lb-ft @ 6,000 rpm (at crankshaft, actual may vary by region/tuning)

Carburetor:

Keihin CVK34 (Constant Velocity)

Fuel Capacity:

11 Liters (2.9 US gal)

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

Cooling Method:

Liquid-cooled

🔧 Transmission

Transmission Type:

6-speed, constant mesh, return type

Clutch:

Wet, multiple-disc, cable operated

Final Drive:

O-ring sealed chain

Transmission Oil Type:

API SE, SF, or SG class, SAE 10W-40 motorcycle oil

Transmission Oil Capacity:

1.9 Liters (2.0 US qt)

📐 Dimensions

Length:

2,180 mm (85.8 in)

Width:

820 mm (32.3 in)

Height:

1,205 mm (47.4 in)

Wheelbase:

1,435 mm (56.5 in)

Ground Clearance:

255 mm (10.0 in)

Dry Weight:

125 kg (275.6 lbs)

Curb Weight:

138 kg (304.2 lbs)

Gvw Rating:

Not specified, but typically limited by rider and cargo capacity.

Front Tire:

80/100-21 51P

Rear Tire:

100/90-18 56P

Front Wheel Size:

21 inch

Rear Wheel Size:

18 inch

🛡️ Safety Features

Crash Safety:

Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP in the same way as cars. Safety depends heavily on rider skill and adherence to traffic laws.

Braking System:

Hydraulic disc brakes front and rear, providing reliable stopping power for a variety of conditions.

Lighting:

Headlight, taillight, brake lights, and turn signals for visibility and signaling intentions to other road users.

Chassis Design:

Steel perimeter frame provides a robust structure for stability and rider control.

Ergonomics:

Designed for rider comfort and control, with a natural riding position suitable for both standing and seated riding.

💡 Technology Features

Instrumentation:

Analog speedometer, tachometer, odometer, trip meter, and various indicator lights (neutral, high beam, turn signals, oil pressure).

ABS:

ABS (Anti-lock Braking System) was not a standard or commonly available option on the 1995 KLX250 model.

Connectivity Features:

No modern connectivity features like Bluetooth or smartphone integration; designed for pure mechanical and electrical systems.

🔧 Maintenance

Engine Oil Change:

Every 3,000 km (1,800 miles) or 6 months, whichever comes first. Check oil level more frequently.

Oil Filter Replacement:

Every 6,000 km (3,600 miles) or 12 months, concurrent with oil change.

Spark Plug Inspection:

Every 3,000 km (1,800 miles). Replace as needed based on condition.

Valve Clearance Adjustment:

Every 6,000 km (3,600 miles) or 12 months. Crucial for engine performance and longevity.

Air Filter Cleaning:

Every 1,500 km (900 miles) or more frequently in dusty conditions. Clean and re-oil.

Chain Lubrication And Adjustment:

Every 500 km (300 miles) or after washing/rain. Adjust slack as per manual specifications.

Engine Oil:

API SE, SF, or SG class, SAE 10W-40 motorcycle oil

Coolant:

Mixture of permanent antifreeze (ethylene glycol-based) and distilled water (50:50 ratio)

Brake Fluid:

DOT 4 hydraulic brake fluid

Fork Oil:

Kawasaki KHL15-10 (or equivalent SAE 10W fork oil)

Carburetor Cleaning:

Carburetors can be prone to clogging from fuel deposits over time, especially if the bike sits for extended periods. Regular cleaning and stabilizer use are recommended.

Valve Adjustment:

Failure to perform regular valve adjustments can lead to poor performance, hard starting, and potential engine damage.

Suspension Seals:

Fork seal leaks can occur with age and usage, requiring replacement to prevent oil loss and contamination.

Electrical Connections:

Corrosion or loosening of electrical connectors can cause intermittent faults in lights, ignition, or charging systems.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki has a long-standing reputation for building high-performance and reliable motorcycles across various categories, including off-road and dual-sport models.

Klx Lineage:

The KLX series has been a cornerstone of Kawasaki's off-road and dual-sport offerings, with continuous development since its introduction. The 1995 model represents a refinement of earlier iterations.

Manufacturing Location:

Primarily manufactured in Japan by Kawasaki Heavy Industries.

Production Period:

The KLX250 model line has seen various iterations and production runs spanning several decades, with the 1995 model being a significant offering in the mid-1990s.

🏆 Awards & Recognition

Industry Acclaim:

While specific awards for the 1995 model may not be widely documented, the KLX line has consistently been praised for its durability, off-road capability, and value in the dual-sport segment.

Reliability Perception:

The KLX250 is generally regarded as a reliable and robust motorcycle, with a strong following among owners who appreciate its straightforward engineering and long-term durability.