🏷️ Basic Information Identification Make: Kawasaki Model: KLX 250 Type: Dual-Sport Motorcycle 👋 Introduction Market Position Segment: Lightweight Dual-Sport Motorcycle Target Audience: Off-road enthusiasts, adventure riders, commuters seeking versatility. Competitive Analysis Key Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250. Key Features Model Attributes: Durable construction, user-friendly ergonomics, capable off-road and on-road performance. Manual Value Proposition: Empowers owners to perform comprehensive maintenance and repairs, saving time and money, and ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service, repair, and maintenance procedures for the Kawasaki KLX 250 motorcycle. Page Count Estimated Page Count: 400-600 Manual Type Manual Classification: Service Workshop Repair Manual Language Primary Language: English Format Digital Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, including disassembly, inspection, assembly, valve adjustment, timing, and component diagnostics. Fuel System: Carburetor (or Fuel Injection system depending on variant) tuning, cleaning, and repair; fuel pump, lines, and tank maintenance. Cooling System: Radiator, fan, coolant flow, and hose inspection and replacement. Ignition System: Spark plugs, ignition coils, CDI unit, and troubleshooting. Exhaust System: Muffler, header pipe, and catalytic converter (if applicable) inspection and replacement. Transmission System: Clutch operation, gear shifting mechanism, transmission overhaul, and lubricant specifications. Drivetrain: Chain and sprockets maintenance, adjustment, and replacement; rear swingarm and linkage lubrication and inspection. Suspension System: Front fork (telescopic) and rear shock absorber servicing, oil changes, seal replacement, and adjustment. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, and disc inspection. Wheel And Tire System: Wheel bearing inspection and replacement, spoke tension adjustment, tire mounting and balancing, and recommended tire pressures. Electrical System: Battery, charging system (stator, regulator/rectifier), lighting, starter motor, and wiring diagrams. Frame And Bodywork: Frame inspection, body panel removal and installation, seat, fuel tank, and handlebar servicing. Procedures Included Maintenance Procedures: Routine maintenance checks, oil changes, filter replacements, chain lubrication, brake adjustments, and general inspection. Diagnostic Procedures: Troubleshooting guides for common problems, electrical system diagnostics, and engine performance issues. Repair Procedures: Step-by-step instructions for component removal, replacement, and repair across all major systems. Overhaul Procedures: Detailed guides for complete engine and transmission overhauls. Assembly Disassembly: Complete instructions for dismantling and reassembling the motorcycle and its components. Technical Depth Depth Of Coverage: Advanced; suitable for experienced DIY mechanics and professional technicians. Diagnostic Capabilities: Includes symptom-based troubleshooting charts and specific diagnostic tests. Tightening Torques: Specific torque values for all critical fasteners and bolts. Clearances: Detailed specifications for valve clearances, piston ring gaps, and other critical component clearances. Wiring Diagrams: Comprehensive, color-coded electrical wiring diagrams. 📊 Manual Specifications File Format Digital Format Details: Searchable PDF with high-resolution images and diagrams. Print Quality Image Resolution: High resolution, suitable for screen viewing and targeted printing. Binding Type Physical Binding If Applicable: N/A (Digital PDF) Paper Type Physical Paper Type If Applicable: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, single-cylinder Displacement: 249 cc (249 cm³) Bore X Stroke: 72.0 mm x 61.2 mm (typical) Cooling System: Liquid-cooled Performance Horsepower: Approx. 22-27 hp (varies by year and market) Torque: Approx. 18-20 Nm (varies by year and market) Fuel System Fuel Delivery: Carburetor (e.g., Keihin CVK34) or Electronic Fuel Injection (EFI) depending on model year/variant. Fuel Type: Unleaded gasoline 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed Clutch Type: Wet, multi-disc Features Gear Ratios: Detailed in manual for specific model variants. 📐 Dimensions Exterior Length: Approx. 2,180 mm (varies) Width: Approx. 800 mm (varies) Height: Approx. 1,170 mm (varies) Wheelbase: Approx. 1,430 mm (varies) Weights Curb Weight: Approx. 130-138 kg (varies) Fuel Tank Capacity: Approx. 7.7 L - 11 L (varies by generation/market) 🛡️ Safety Features Ratings Safety Certification: Meets relevant motorcycle safety standards for production markets. Active Features Braking System Type: Disc brakes front and rear. ABS available on some later models. Passive Features Lighting System: Halogen or LED headlight, tail light, and turn signals. 💡 Technology Features Infotainment Instrument Cluster: Digital LCD display with speedometer, tachometer, odometer, trip meter, fuel gauge, clock, and indicator lights. Driver Assistance ABS Availability: Available on select later model years (e.g., KLX250 ABS). Connectivity Connectivity Features: None (basic motorcycle design). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-6,000 km or 6-12 months (refer to manual for specific model year). Valve Adjustment Interval: Every 6,000-12,000 km (refer to manual). Chain Maintenance: Lubrication and tension check every 500-1,000 km. Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher, JASO MA certified (verify in manual). Coolant Type: Permanent type ethylene glycol based coolant (50% solution with distilled water). Brake Fluid Type: DOT 4 (verify in manual). Known Issues Common Wear Items: Clutch plates, brake pads, chain and sprockets, fork seals. Potential Engine Concerns: Valve seat wear (rare), carburetor jetting issues (on older models) if not properly maintained. 📚 Vehicle History Brand Heritage Manufacturer:...
Searchable PDF with high-resolution images and diagrams.
Print Quality
Image Resolution:
High resolution, suitable for screen viewing and targeted printing.
Binding Type
Physical Binding If Applicable:
N/A (Digital PDF)
Paper Type
Physical Paper Type If Applicable:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, DOHC, single-cylinder
Displacement:
249 cc (249 cm³)
Bore X Stroke:
72.0 mm x 61.2 mm (typical)
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 22-27 hp (varies by year and market)
Torque:
Approx. 18-20 Nm (varies by year and market)
Fuel System
Fuel Delivery:
Carburetor (e.g., Keihin CVK34) or Electronic Fuel Injection (EFI) depending on model year/variant.
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed
Clutch Type:
Wet, multi-disc
Features
Gear Ratios:
Detailed in manual for specific model variants.
📐 Dimensions
Exterior
Length:
Approx. 2,180 mm (varies)
Width:
Approx. 800 mm (varies)
Height:
Approx. 1,170 mm (varies)
Wheelbase:
Approx. 1,430 mm (varies)
Weights
Curb Weight:
Approx. 130-138 kg (varies)
Fuel Tank Capacity:
Approx. 7.7 L - 11 L (varies by generation/market)
🛡️ Safety Features
Ratings
Safety Certification:
Meets relevant motorcycle safety standards for production markets.
Active Features
Braking System Type:
Disc brakes front and rear. ABS available on some later models.
Passive Features
Lighting System:
Halogen or LED headlight, tail light, and turn signals.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD display with speedometer, tachometer, odometer, trip meter, fuel gauge, clock, and indicator lights.
Driver Assistance
ABS Availability:
Available on select later model years (e.g., KLX250 ABS).
Connectivity
Connectivity Features:
None (basic motorcycle design).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-6,000 km or 6-12 months (refer to manual for specific model year).
Valve Adjustment Interval:
Every 6,000-12,000 km (refer to manual).
Chain Maintenance:
Lubrication and tension check every 500-1,000 km.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified (verify in manual).
Coolant Type:
Permanent type ethylene glycol based coolant (50% solution with distilled water).
Brake Fluid Type:
DOT 4 (verify in manual).
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals.
Potential Engine Concerns:
Valve seat wear (rare), carburetor jetting issues (on older models) if not properly maintained.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Model Evolution
Key Generations:
The KLX 250 has seen several iterations, notably the early carbureted models and later fuel-injected versions with updated styling and features (e.g., KLX250S, KLX250SF, KLX250). The manual covers specific variants which should be confirmed by the user.
Production
Production Period:
Continuously produced since the 1990s, with significant updates in the 2000s and beyond.
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