🏷️ Basic Information

Make:

Kawasaki

Model:

KLX250

Model Variant:

KLX250R

Model Codes Covered:

Specific codes for 1993-1997 KLX250R models

👋 Introduction

Market Position:

The Kawasaki KLX250R was positioned as a capable dual-sport motorcycle, bridging the gap between trail riding and on-road usability, popular for adventure touring and off-road exploration.

Competitive Analysis:

Competed against other dual-sport offerings of the era such as Yamaha XT series, Honda XR series, and Suzuki DR series, differentiating itself with its specific handling characteristics and engine tuning.

Key Features:

Durable single-cylinder engine, capable suspension, robust chassis, and a focus on off-road performance with street-legal capability.

📋 Manual Details

Coverage Years:

1993, 1994, 1995, 1996, 1997

Regional Coverage:

Likely North American and potentially global specifications depending on original manual origin.

Page Count:

Estimated 400-600 pages (typical for a comprehensive service manual of this era).

Manual Type:

Service Repair Manual

Language:

English

Format:

Likely PDF (digital download) or potentially a printed manual.

📖 Manual Coverage

Engine Mechanical:

Complete engine disassembly, assembly, inspection, and repair procedures for the 250cc single-cylinder engine, including cylinder head, valves, piston, crankshaft, and lubrication system.

Fuel System:

Carburetor identification, adjustment, disassembly, cleaning, and reassembly; fuel tank, fuel lines, and petcock service.

Ignition System:

CDI ignition system components, troubleshooting, timing adjustment, and spark plug specifications.

Cooling System:

Liquid cooling system maintenance, radiator, hoses, thermostat, and coolant specifications.

Transmission:

Gearbox disassembly, inspection, and reassembly; clutch operation and service; gear shift mechanism.

Chassis Frame:

Frame inspection, steering head bearing service, and general chassis component checks.

Front Suspension:

Front fork disassembly, service, oil replacement, seal replacement, and spring specifications.

Rear Suspension:

Monoshock rear suspension linkage service, shock absorber inspection and adjustment, and swingarm bearing maintenance.

Front Brake System:

Hydraulic disc brake system service, caliper disassembly, pad replacement, fluid flush, and master cylinder overhaul.

Rear Brake System:

Disc brake system service, caliper disassembly, pad replacement, fluid flush, and master cylinder overhaul.

Wheels Tires:

Spoke wheel maintenance, rim inspection, tire mounting and balancing, and recommended tire pressures.

Electrical System:

Wiring diagrams, component testing (lights, horn, signals, starter), battery maintenance, and fuse specifications.

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, brake system checks.

Troubleshooting:

Diagnostic charts and procedures for common starting, running, and electrical issues.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, and electrical system component repairs.

Special Tools:

Identification and use of specialized tools required for specific repair procedures.

Technical Depth:

Comprehensive, covering all aspects from basic adjustments to complete engine and component overhauls, suitable for experienced mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Likely searchable text (OCR'd) for efficient information retrieval.

Print Quality:

High-resolution diagrams and text for clear readability.

Binding Type:

N/A (for PDF format). If printed, would typically be spiral-bound or perfect-bound for workshop use.

Paper Type:

N/A (for PDF format). If printed, would typically be durable, glossy paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Type:

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

Displacement:

249 cc (approx. 249 cubic centimeters)

Bore X Stroke:

72.0 x 61.2 mm (typical for this generation)

Compression Ratio:

Approx. 10.0:1 to 11.0:1 (depending on specific model year variations)

Horsepower:

Estimated 28-32 HP @ 7,500 RPM (varies by market and tuning)

Torque:

Estimated 20-23 lb-ft @ 6,000 RPM (varies by market and tuning)

Fuel Delivery:

Carbureted (e.g., Keihin CV carburetor, likely 34mm or similar)

Fuel Type:

Unleaded gasoline, octane rating typically 87 or higher

Oil Type:

API SE, SF, SG or SH classification, SAE 10W-40 or 10W-50 motorcycle specific oil recommended. Refer to manual for exact specification.

Oil Capacity:

Approx. 1.5 - 1.8 Liters (with filter change). Refer to manual for exact capacity.

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Kawasaki Coolant or equivalent).

Coolant Capacity:

Approx. 1.0 - 1.2 Liters. Refer to manual for exact capacity.

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multi-disc, manual operation

Final Drive:

O-ring sealed chain

Transmission Oil Type:

API GL-4, SAE 80 or 90 transmission oil. Refer to manual for exact specification.

Transmission Oil Capacity:

Approx. 0.6 - 0.8 Liters. Refer to manual for exact capacity.

📐 Dimensions

Length:

Approx. 2190 mm (refer to specific model year for exact)

Width:

Approx. 835 mm (refer to specific model year for exact)

Height:

Approx. 1250 mm (refer to specific model year for exact)

Wheelbase:

Approx. 1430 mm (refer to specific model year for exact)

Ground Clearance:

Approx. 255 mm (refer to specific model year for exact)

Dry Weight:

Approx. 116 kg (refer to specific model year for exact)

Curb Weight:

Approx. 127 kg (with all necessary fluids and a full tank of fuel, refer to manual)

Fuel Capacity:

Approx. 10.0 Liters (including reserve). Refer to manual for exact capacity.

Seat Height:

Approx. 875 mm (refer to specific model year for exact)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles are not typically subjected to formal crash test ratings like automobiles.)

Active Safety Features:

Front and rear disc brakes for effective stopping power, well-balanced chassis for stable handling.

Passive Safety Features:

Durable frame construction, headlight, taillight, and turn signals for visibility.

💡 Technology Features

Infotainment Systems:

N/A (This is a 1990s era off-road motorcycle, lacking modern infotainment features.)

Driver Assistance Systems:

N/A (No electronic rider aids or driver assistance systems on this model.)

Connectivity Features:

N/A (No electronic connectivity features.)

🔧 Maintenance

Engine Oil Change:

Every 3,000 km or 6 months, whichever comes first. Refer to manual for exact intervals.

Air Filter Cleaning:

Every 1,000 km or as needed in dusty conditions. Replacement recommended annually or as per wear.

Spark Plug Inspection:

Every 3,000 km. Replacement intervals will be detailed in the manual.

Chain Adjustment Lubrication:

Every 500 km or as needed. Refer to manual for precise tension specification.

Brake Fluid Flush:

Every 12,000 km or 12 months. Refer to manual for specific interval.

Coolant Replacement:

Every 24,000 km or 24 months. Refer to manual for specific interval.

Engine Oil Specification:

API SE, SF, SG or SH classification, SAE 10W-40 or 10W-50 motorcycle specific oil. Refer to manual for exact specification.

Transmission Oil Specification:

API GL-4, SAE 80 or 90 transmission oil. Refer to manual for exact specification.

Brake Fluid Specification:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant Specification:

Ethylene glycol-based coolant with corrosion inhibitors.

Known Issues:

Potential wear on valve seats, carburetor jetting issues if not properly maintained, starter clutch wear, and general aging of rubber components (hoses, seals) due to age. The manual will provide troubleshooting for these and more.

📚 Vehicle History

Brand Heritage:

Kawasaki has a long-standing reputation for producing robust and performance-oriented motorcycles, particularly in the off-road and dual-sport segments.

Model Evolution:

The KLX250 series evolved from earlier Kawasaki dual-sport models, with the KLX250R representing a significant iteration focused on enhanced off-road capability and performance for its era. Subsequent models would introduce fuel injection and further refinements.

Production Years:

The KLX250R model was produced in the mid-to-late 1990s. This manual specifically covers the 1993-1997 model years.

Manufacturing Locations:

Likely manufactured in Japan.

🏆 Awards & Recognition

Awards Recognitions:

While specific awards for the 1993-1997 KLX250R are not readily cataloged, the model was well-regarded for its performance in its class and contributed to Kawasaki's strong presence in the dual-sport market.