The Kawasaki KLX250, produced for the model years 1993 through 1997, is a versatile dual-sport motorcycle renowned for its lightweight chassis, capable off-road suspension, and reliable liquid-cooled, four-stroke engine. Designed for enthusiasts and riders seeking a balance between trail performance and street legality, this first-generation model offers a robust platform for both adventure and daily commuting. Its engineering prioritizes rider engagement and dependability, making it a capable competitor in its segment. This comprehensive Workshop Service Manual provides detailed guidance for the maintenance, repair, and troubleshooting of your Kawasaki KLX250. It covers all essential systems, including engine mechanicals, fuel and ignition systems, cooling, transmission, clutch, suspension, brakes, and the electrical system. With step-by-step disassembly and assembly instructions, diagnostic procedures, and precise torque specifications, this manual serves as an indispensable resource for owners and technicians to ensure the optimal performance and longevity of the motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 Applicable Years: 1993, 1994, 1995, 1996, 1997 Generation Generation Identifier: First Generation (KLX250) Codes Chassis Codes: KLX250-D1, KLX250-D2, KLX250-D3, KLX250-D4, KLX250-D5 👋 Introduction Market Position Segment: Dual-Sport / Enduro Motorcycle Target Audience: Enthusiasts, off-road riders, daily commuters seeking versatility Competitive Analysis Competitors: Honda XR250, Yamaha WR250, Suzuki DR250 Key Features Features: Lightweight chassis, capable off-road suspension, reliable engine, street-legal for versatility 📋 Manual Details Coverage Areas Geographic Coverage: Global (specific regional variations may exist not detailed) Page Count Total Pages: 299 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, top-end, bottom-end, valve timing, piston assembly, crankshaft, connecting rod, cylinder head, cylinder block Fuel System: Carburetor disassembly, adjustment, cleaning, fuel pump, fuel lines, fuel tank Ignition System: CDI unit, ignition coils, spark plugs, timing Cooling System: Radiator, coolant hoses, water pump, thermostat Transmission: Gearbox disassembly, inspection, lubrication, shift mechanism Clutch: Clutch plate inspection, operation, adjustments Suspension Front: Fork disassembly, seal replacement, oil levels, spring rates, adjustments Suspension Rear: Monoshock absorber, linkage system, swingarm, bearing maintenance Brakes Front: Caliper overhaul, piston seals, brake pads, brake disc inspection, fluid replacement Brakes Rear: Caliper overhaul, brake pads, brake disc inspection, fluid replacement Electrical System: Wiring diagrams, lighting, battery, charging system, starter motor, fuses Frame And Bodywork: Frame inspection, fairings, seat, handlebars, footpegs Wheels And Tires: Wheel bearing maintenance, spoke tension, tire pressure, tire inspection Procedures Included Maintenance Schedule: Detailed preventative maintenance intervals for all major components Troubleshooting: Comprehensive diagnostic procedures for common and uncommon issues Disassembly And Assembly: Step-by-step instructions for all major component overhauls and replacements Torque Specifications: Precise torque values for critical fasteners throughout the motorcycle Adjustments: Carburetor idle, clutch lever, brake levers, chain tension, suspension settings Special Tools: Identification of specific tools required for certain procedures Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic servicing to complete engine and transmission rebuilds Diagnostic Capability: Advanced diagnostic charts and troubleshooting guides for electrical and mechanical faults Rebuild Instructions: Detailed instructions for rebuilding major components like the engine, transmission, and suspension 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable, common for professional PDF manuals Print Quality Print Readability: Designed for clarity, suitable for printing specific sections Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Completeness Manual Scope: Full workshop manual covering all aspects of maintenance, repair, and troubleshooting. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, single-cylinder, liquid-cooled Displacement: 249 cc (approx.) Bore X Stroke: 72.0 x 61.2 mm (typical for this generation) Compression Ratio: 11.0:1 (typical) Performance Horsepower: Approx. 25-30 HP (Varies by market and specific tuning) Torque: Approx. 20-23 Nm (Varies by market and specific tuning) Fuel System Carburetion: Mikuni VM26SS (typical for this generation), possibly TM series on later models Fuel Type: Unleaded gasoline Lubrication Oil Capacity: Approx. 1.5 - 2.0 liters (including filter), refer to manual for exact spec Oil Type: SAE 10W-40 or 20W-50 motorcycle specific, API SG or higher (refer to manual for exact spec) 🔧 Transmission Standard Type: 6-speed constant mesh Optional Optional Types: N/A Features Clutch Type: Wet, multi-disc Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2,180 mm (Varies slightly by model year) Width: Approx. 810 mm (Varies slightly by model year) Height: Approx. 1,205 mm (Varies slightly by model year) Wheelbase: Approx. 1,430 mm (Varies slightly by model year) Weights Dry Weight: Approx. 119 kg (Varies slightly by model year) Wet Weight: Approx. 132 kg (with fluids and full tank) Fuel Capacity: Approx. 10 liters (including reserve) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles typically do not have standardized crash test ratings like cars) Active Features Braking System: Front and rear disc brakes Lighting: Halogen headlight, taillight, turn signals (street legal) Passive Features Frame Construction: High-tensile steel frame for rigidity and impact resistance 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation) Driver Assistance Driver...