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Kawasaki KLX250 1993-1997 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 Model Variant: Dual-Sport / Off-Road Motorcycle Product Type: Factory Service Repair Manual Codes Product Sku: KWS-KLX250-9397-FSRM 👋 Introduction Market Position Segment: Lightweight...
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🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250
Model Variant:
Dual-Sport / Off-Road Motorcycle
Product Type:
Factory Service Repair Manual
Codes
Product Sku:
KWS-KLX250-9397-FSRM
👋 Introduction
Market Position
Segment:
Lightweight dual-sport/enduro motorcycle, popular for trail riding, off-road exploration, and light commuting.
Target Audience:
Enthusiast owners, mechanics, and restoration specialists looking for authoritative repair information.
Competitive Analysis
Competitors Era:
Honda XR250L, Yamaha WR250, Suzuki DR250SE.
Key Features Vehicle
Engine Type:
Robust and reliable liquid-cooled 4-valve DOHC single-cylinder engine, known for its tractable power delivery.
Suspension:
Often featured advanced suspension components for its class, with adjustable front forks and a linkage-driven rear monoshock for capable off-road performance.
Versatility:
Designed as a true dual-sport, balancing off-road capability with street legality and moderate on-road comfort.
Manual Value
Repair Confidence:
Empowers owners to perform a wide range of maintenance and repairs, reducing reliance on external service providers.
Resale Value:
A well-maintained motorcycle with a documented service history (supported by this manual) can command a higher resale value.
📋 Manual Details
Coverage Areas
Covered Years:
1993, 1994, 1995, 1996, 1997
Engine Coverage:
249cc, 4-stroke, Liquid-Cooled, DOHC, Single-Cylinder
Model Variants Covered:
All KLX250 models within the specified year range, including potential variations in carburetor or emissions equipment.
Page Count
Page Count:
Approx. 300-400 pages (typical for this era's factory manuals)
Manual Type
Manual Type:
Factory Service Manual
Language
Language:
English
Format
Format:
Printed, Book Format
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of the engine. Includes cylinder head, piston, rings, crankshaft, connecting rod, valve train, timing chain, and lubrication system.
Fuel System:
Carburetor (model specific, likely Keihin), fuel pump, fuel lines, fuel tank maintenance, and troubleshooting.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, and coolant specifications.
Ignition System:
CDI unit, ignition coil, spark plug specifications, timing procedures, and troubleshooting.
Transmission:
Clutch operation, gearbox disassembly, inspection, repair, and lubrication. Includes gear ratios and shift mechanism.
Drivetrain:
Chain and sprockets maintenance, adjustment, and replacement. Rear wheel hub and drive bearing service.
Suspension Front:
Front forks (USD or conventional depending on specific sub-model), oil levels, seals, springs, damping adjustments, and rebuild procedures.
Suspension Rear:
Monoshock rear suspension, linkage system, shock absorber service, spring preload adjustment, and bearing maintenance.
Brakes Front:
Hydraulic disc brake system, caliper service, pad replacement, master cylinder, brake lines, fluid type, and bleeding procedures.
Brakes Rear:
Hydraulic disc brake system, caliper service, pad replacement, master cylinder, brake lines, fluid type, and bleeding procedures.
Wheels Tires:
Spoke wheel maintenance, rim care, tire mounting/removal, tube replacement, and balancing.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting (headlight, taillight, turn signals), horn, starter system, and fuse identification.
Chassis Frame:
Frame inspection, headstock bearings, swingarm pivot, and general chassis component service.
Bodywork Trim:
Fairings, fenders, seat, fuel tank cover, and other cosmetic component removal, installation, and care.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustments, air filter cleaning, spark plug checks, brake fluid flushes, and general inspection points.
Troubleshooting Diagnostics:
Step-by-step diagnostic flowcharts for common problems related to starting, running, electrical faults, and performance issues.
Engine Repair:
Detailed instructions for internal engine component repair, including decarbonization, gasket replacement, and part tolerance checks.
Carburetor Rebuild:
Complete carburetor disassembly, cleaning, jetting information, synchronization, and adjustment procedures.
Suspension Rebuild:
Fork seal replacement, damper rod service, shock absorber re-pressurization (if applicable to the era), and bushing replacement.
Brake System Service:
Hydraulic system bleeding, caliper piston service, master cylinder overhaul, and brake pad installation.
Electrical Component Testing:
Testing of ignition components, charging system output, and other electrical parts using a multimeter.
Wiring Diagram Interpretation:
Detailed, component-level wiring diagrams for troubleshooting electrical issues.
Torque Specifications:
Precise torque values for all critical fasteners throughout the motorcycle.
Special Tools:
Identification and usage of any specialized tools required for specific repair procedures.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to full engine and chassis rebuilds).
Diagnostic Capability:
High - covers common failure points and provides systematic troubleshooting steps.
Repair Scope:
Encompasses all mechanical and electrical systems of the motorcycle.
📊 Manual Specifications
File Format
File Format:
Physical print (not digital PDF unless otherwise specified for derivative products).
Print Quality
Print Quality:
High-quality professional printing with clear diagrams and text.
Binding Type
Binding Type:
Stapled or perfect bound, designed for workshop use (may vary slightly based on original factory production).
Paper Type
Paper Type:
Durable, semi-gloss paper stock suitable for a workshop environment.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-cooled, DOHC, 4-valve, Single Cylinder
Displacement:
249 cc
Bore X Stroke:
72.0 x 61.2 mm (typical for this generation)
Compression Ratio:
11.0:1 (typical)
Performance
Horsepower:
Approximately 27-30 HP @ 7500-8000 RPM (subject to tuning and specific market regulations)
Torque:
Approximately 20-22 lb-ft @ 6000-6500 RPM (subject to tuning and specific market regulations)
Fuel System
Fuel Delivery:
Carburetor (e.g., Keihin CVK34 or similar)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication System
Oil Type:
SAE 10W-40 motorcycle oil, API SG or higher
Oil Capacity:
Approx. 1.6 - 1.8 Liters (with filter change)
Ignition
Ignition System:
Digital CDI with electronic advance
Spark Plug:
NGK CR8E or equivalent (verify with manual)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-disc
Features
Gear Ratios:
Specific gear ratios detailed within the manual, crucial for performance tuning and understanding.
Final Drive:
O-ring sealed chain, 520 pitch (typical)
📐 Dimensions
Exterior
Length:
Approx. 2,235 mm (88.0 in)
Width:
Approx. 800 mm (31.5 in)
Height:
Approx. 1,160 mm (45.7 in)
Wheelbase:
Approx. 1,435 mm (56.5 in)
Ground Clearance:
Approx. 255 mm (10.0 in)
Weights
Dry Weight:
Approx. 121 kg (267 lbs)
Wet Weight:
Approx. 130 kg (287 lbs) (with all fluids)
Fuel Capacity:
Approx. 10 Liters (2.6 US gal)
🛡️ Safety Features
Ratings
Safety Features Motorcycle:
Dual disc brakes provide significant stopping power for its class. Headlight, taillight, and brake light for visibility.
Active Features
Braking System:
Front: Dual hydraulic disc; Rear: Hydraulic disc.
Lighting:
Halogen headlight, LED or incandescent taillight/brake light, turn signals.
Passive Features
Frame Construction:
High-tensile steel perimeter frame for rigidity and impact resistance.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights. Basic and functional for its era.
Driver Assistance
ABS:
No Anti-lock Braking System (ABS) equipped on this model.
Connectivity
Diagnostic Ports:
No electronic diagnostic ports; relies on mechanical checks and visual inspection as guided by the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 2,000-3,000 km (1,200-1,800 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1,000-1,500 km (600-900 miles) or as needed based on riding conditions.
Spark Plug Check:
Every 3,000-4,000 km (1,800-2,500 miles).
Valve Clearance Check:
Every 6,000-8,000 km (3,700-5,000 miles) or every 12 months.
Brake Fluid Flush:
Every 12 months or 24 months, depending on conditions.
Fluid Specifications
Engine Oil:
SAE 10W-40, API SG or higher, JASO MA certified.
Coolant:
Ethylene glycol based, 50/50 mixture with distilled water. Kawasaki Coolant Type 1 or equivalent.
Brake Fluid:
DOT 3 or DOT 4 (verify with manual).
Fork Oil:
Specific viscosity and amount detailed in manual (often 10W or 15W).
Known Issues
Carburetor Cleaning:
Carburetors can become gummed up with age and infrequent use, requiring cleaning and jetting.
Suspension Seals:
Fork seals are prone to wear and leakage, especially with off-road use, necessitating replacement.
Cam Chain Tensioner:
Some models may develop noise from the cam chain tensioner; manual provides inspection and adjustment procedures.
Exhaust Flange Gasket:
The exhaust header flange gasket can sometimes leak, requiring replacement.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long history of producing high-performance motorcycles, known for innovation and durability across various segments, including off-road and dual-sport.
Model Evolution
Klx Lineage:
The KLX250 model is part of a lineage of Kawasaki dual-sport motorcycles that have evolved to meet changing performance and emissions standards. This 1993-1997 generation represents a significant iteration of the model.
Production
Manufacturing Location:
Japan (primarily)
Generation Era:
This specific manual covers the K-L model generation, which saw updates in styling and engine tuning throughout its production run.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Praised by contemporary reviews for its capable suspension, reliable engine, and balanced performance in the dual-sport category.
Ratings
Durability Rating:
Generally considered a durable and long-lasting motorcycle with proper maintenance.