Vehicle Segment:
Dual-sport motorcycle, known for versatility on and off-road.
Target Audience:
Riders seeking adventure, commuting, or trail riding capabilities.
Competitors:
Honda CRF250L/CRF250 Rally, Yamaha WR250R, Suzuki DR-Z400S.
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder engine.
Suspension:
Long-travel, adjustable front forks and rear monoshock suspension for off-road capability.
Braking:
Disc brakes front and rear, often with optional ABS.
Frame:
Perimeter frame for rigidity and light weight.
Primary Coverage:
Mechanical and electrical systems, repair, maintenance, troubleshooting
Specific Systems:
Engine, transmission, fuel system, ignition system, electrical system, chassis, suspension, brakes, cooling system, exhaust system, lubrication system
Estimated Pages:
Approximately 400-500 pages (typical for this type of comprehensive manual)
Type:
Factory Service Manual / Repair Manual
Format:
Digital (PDF likely), potentially available in print
Engine Mechanical:
Detailed disassembly, inspection, and reassembly procedures for all engine components including cylinder head, pistons, crankshaft, connecting rods, valve train, and more.
Engine Management:
Fuel injection system (EFI), ignition system diagnostics, sensor testing, ECU troubleshooting.
Transmission Clutch:
Clutch assembly, gearbox disassembly and inspection, gear shifting mechanism, lubrication.
Cooling System:
Radiator, fan, thermostat, coolant flow, pressure testing.
Fuel System:
Fuel pump operation, fuel injectors, fuel pressure regulation, fuel tank and lines.
Lubrication System:
Oil pump, oil filter, oil passages, oil capacity and specifications.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, fuses, relays.
Chassis Frame:
Frame inspection, swingarm, steering system.
Suspension Front:
Front fork disassembly, seal replacement, oil type and level, spring rates, damping adjustments.
Suspension Rear:
Rear shock absorber, linkage system, adjustment procedures.
Braking System:
Brake pad replacement, caliper service, master cylinder maintenance, bleeding procedures, hydraulic fluid specifications.
Wheels Tires:
Wheel bearing inspection, tire pressure recommendations, spoke tension (if applicable).
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic flowcharts for common issues such as starting problems, engine performance issues, electrical malfunctions.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension rebuilds, electrical system repairs.
Component Replacement:
Step-by-step guides for replacing parts like brake calipers, clutch plates, spark plugs, air filters, battery, etc.
Torque Specifications:
Precise torque values for all critical fasteners and bolts.
Wiring Diagrams:
Comprehensive and detailed electrical wiring schematics for accurate troubleshooting and repair.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls.
Diagnostics:
In-depth diagnostic procedures for identifying and resolving mechanical and electrical faults.
Rebuild Procedures:
Detailed instructions for rebuilding major components like the engine and transmission.
Digital Format:
PDF (Portable Document Format)
Searchability:
Likely searchable text, allowing for quick information retrieval.
Illustrations:
High-quality diagrams, line drawings, and photographs for clarity.
Print Option:
If printed, typically spiral-bound or comb-bound for lay-flat use in a workshop environment.
Print Option:
If printed, often on durable, semi-gloss paper to withstand workshop conditions.
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.1 mm (typical for this engine)
Compression Ratio:
11.0:1 (typical)
Horsepower:
Approximately 30-34 HP (Horsepower) depending on year and emissions standards.
Torque:
Approximately 18-20 lb-ft (Pound-feet) depending on year.
Induction:
Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Ignition System:
Digital CDI with electronic advance
Oil Type:
API SG, SH, SJ, SL or SM, SAE 10W-40 motorcycle oil
Oil Capacity:
Approximately 1.7 liters (1.8 US qt) without filter change; 1.9 liters (2.0 US qt) with filter change.
Display:
Digital LCD instrument panel displaying speedometer, tachometer, odometer, trip meters, clock, fuel gauge, and indicator lights.
ABS:
Available ABS on select models provides enhanced braking control.
No Specific Connectivity:
As a performance-oriented dual-sport, advanced smartphone connectivity or integrated GPS is typically not featured.
Oil Change:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first.
Oil Filter Change:
Every 2nd oil change, or as per manual recommendation.
Air Filter Cleaning:
Every 1,000-2,000 km (600-1,200 miles), or more frequently in dusty conditions.
Spark Plug Check:
Every 4,000-6,000 km (2,500-3,700 miles).
Chain Adjustment Lubrication:
Every 500-1,000 km (300-600 miles), or as needed.
Valve Clearance Check:
Typically at 10,000-15,000 km (6,000-9,000 miles) intervals.
Coolant Type:
High-quality ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals can be subject to wear with regular use.
Efi System:
Potential for clogged fuel injectors or issues with the fuel pump if fuel quality is poor or maintenance is neglected.
Suspension Performance:
As a dual-sport, aggressive off-road use can accelerate wear on suspension components; regular maintenance is key.
Kawasaki Offroad:
Kawasaki has a long and successful history in off-road and dual-sport motorcycle racing and production.
Klx Lineage:
The KLX series has evolved over decades, with the KLX250 being a staple known for its durability and off-road prowess.
Introduction Year:
The KLX250 platform has seen various iterations since the late 1970s/early 1980s. Specific KLX250R designation implies a focus on off-road/competition variants, though many service manuals cover both road-legal and off-road focused versions.
Major Updates:
Significant updates often include engine refinements (e.g., fuel injection adoption), suspension improvements, and chassis tweaks to enhance performance and rider comfort.
