Market Position:
The Kawasaki KLX250/KLX250R was positioned as a capable dual-sport and off-road motorcycle, appealing to riders seeking versatility for trail riding and light street use. This 1993 model represents a significant iteration of Kawasaki's off-road lineage.
Competitors 1993:
Competed with other dual-sport and off-road motorcycles of the era, such as the Yamaha WR250, Honda XR250L, and Suzuki DR250S.
Key Features Vehicle:
Liquid-cooled, four-valve, single-cylinder engine, strong off-road suspension, often featured a headlight and taillight for dual-sport legality, robust construction for off-road durability.
Manual Value:
This comprehensive service manual is indispensable for owners and mechanics aiming to maintain, diagnose, and repair the 1993 Kawasaki KLX250/KLX250R. It provides factory-level detail crucial for preserving the performance and longevity of this iconic dual-sport.
Engine System:
Top end (cylinder, piston, valves), bottom end (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable), fuel system (carburetor tuning, cleaning), exhaust system.
Transmission System:
Clutch operation and adjustment, gear shifting mechanism, transmission gears, lubrication, troubleshooting.
Chassis System:
Frame inspection and repair, front suspension (forks, damping, seals), rear suspension (shock absorber, linkage, bearings), steering system, wheel bearings, swingarm.
Electrical System:
Ignition system (CDI, spark plug), charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), starting system (kick start), wiring diagrams for all circuits.
Braking System:
Front and rear brake systems (drum or disc depending on variant), brake fluid specifications, bleeding procedures, pad/shoe replacement, caliper/master cylinder service.
Fuel System:
Carburetor model (e.g., Keihin CVK), jetting specifications, float bowl adjustment, fuel line routing, fuel tank maintenance.
Bodywork And Trim:
Fairing removal and installation, seat, fenders, fuel tank cover, graphics.
Maintenance Procedures:
Oil change intervals and specifications, air filter cleaning/replacement, spark plug inspection and replacement, chain adjustment and lubrication, brake adjustment, tire pressure checks, general lubrication points.
Repair Procedures:
Engine rebuilds (top and bottom end), carburetor overhaul, suspension fork seal replacement, wheel bearing replacement, clutch plate replacement, electrical component testing and replacement.
Troubleshooting Guides:
Diagnostic flowcharts for common issues like starting problems, poor engine performance, electrical failures, braking issues.
Torque Specifications:
Detailed torque values for all critical fasteners (engine, chassis, suspension, brakes).
Wiring Diagrams:
Comprehensive electrical system diagrams for all circuits, component identification.
Depth Level:
Comprehensive Workshop Level. Covers routine maintenance to full engine and chassis overhauls.
Diagnostic Capabilities:
Detailed troubleshooting section with symptoms and likely causes.
Rebuild Instructions:
Step-by-step instructions for major component rebuilds (engine, transmission, suspension).
Engine Type:
Four-stroke, Liquid-cooled, DOHC, 4-valve
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
10.0:1 (Typical for this generation)
Carburetor:
Keihin CVK34 (Typical)
Horsepower Estimated:
~28-30 hp @ 7500 rpm (Estimated for KLX250R)
Torque Estimated:
~26 Nm @ 6000 rpm (Estimated for KLX250R)
Fuel Type:
Unleaded gasoline, Octane rating 87 or higher
Fuel Tank Capacity:
Approx. 10-12 Liters (Varies slightly by sub-model)
Oil Type:
SAE 10W-40 API SG or higher
Oil Capacity:
Approx. 1.7 - 1.9 Liters (with filter change)
Safety Ratings:
Motorcycles of this era typically do not have standardized government safety ratings like automobiles. Focus is on mechanical integrity and rider control.
Active Safety Features:
Effective braking system (disc front, drum/disc rear), responsive suspension for terrain management, good rider ergonomics.
Passive Safety Features:
Sturdy frame construction, protective bodywork (fenders, shrouds), robust lighting for visibility.
Engine Oil Change Interval:
Every 3,000 km or 6 months (or as specified in the manual for severe use).
Air Filter Cleaning Interval:
Every 1,000 km, or more frequently in dusty conditions.
Spark Plug Inspection Interval:
Every 3,000 km or annually.
Chain Lubrication Interval:
Every 500 km and after washing or riding in rain.
Valve Clearance Check Interval:
Every 6,000 km or annually.
Engine Oil Specification:
SAE 10W-40, API SG or higher
Coolant Type:
Ethylene glycol based antifreeze (50% mixture with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4
Fork Oil Type And Level:
Kawasaki KHL15-10 (or equivalent SAE 10W fork oil), specified level in manual (typically around 100-120mm from top of inner tube with spring removed).
Common Issues 1993 Klx250:
Carburetor jetting sensitivity to altitude/temperature, potential wear in the cam chain tensioner, fork seal leaks, and typical age-related electrical connection corrosion.
Troubleshooting Focus Areas:
Starting difficulties, hesitation or sputtering under acceleration, weak spark, and suspension performance degradation are common areas requiring attention.
