🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 / D-Tracker / KLX250R Model Aliases: KLX250SR (Japan market variant) Model Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Engine Codes: KL250-G (example - actual specific codes may vary by sub-model and market) 👋 Introduction Market Position Category: Dual-sport / Supermoto Motorcycle Target Audience: Off-road enthusiasts, commuters, Supermoto riders. Competitive Analysis Competitors Historical: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250, KTM 250 EXC. Key Features Versatility: Adaptable for both off-road trails and street riding (especially D-Tracker variant). Reliability: Known for robust Kawasaki engineering and durability. Performance: Adequate power for its class, agile handling. 📋 Manual Details Coverage Areas Coverage Scope: Complete Workshop Service and Repair All Models Included: True All Engines Included: True All Trim Levels Included: True All Transmission Types Included: True Page Count Estimated Page Count: High (Typically 400+ pages for a comprehensive service manual covering this many years) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, overhaul, cylinder head, cylinder block, crankshaft, pistons, connecting rods, valve train, timing system. Fuel System: Carburetor(s) disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel tank maintenance. Ignition System: Ignition timing, spark plugs, ignition coils, CDI unit, wiring. Cooling System: Radiator, coolant, hoses, thermostat, water pump. Exhaust System: Exhaust pipes, muffler, mounting. Transmission: Clutch operation, gearbox disassembly, assembly, gear shift mechanism, lubrication. Drivetrain: Chain drive system (sprockets, chain inspection, adjustment, replacement). Suspension Front: Front fork disassembly, assembly, oil change, seal replacement, springs. Suspension Rear: Rear shock absorber, linkage system, swingarm maintenance. Brakes Front: Brake caliper, master cylinder, brake lines, brake pads, brake disc inspection and replacement. Brakes Rear: Brake drum or disc (depending on specific D-Tracker/KLX250R variant), brake shoes, brake lever/pedal adjustment. Wheels And Tires: Wheel bearing maintenance, spoke tension, tire inspection and replacement, rim specifications. Electrical System: Wiring diagrams, battery maintenance, lighting system, charging system (stator, regulator/rectifier), starter motor, horn. Frame And Bodywork: Frame inspection, handlebars, fuel tank removal/installation, seat, fenders, plastics. Controls: Throttle controls, clutch lever, brake lever, footpegs, shifter adjustment. Instruments And Gauges: Speedometer, tachometer, indicator lights, troubleshooting. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain lubrication and adjustment, air filter cleaning/replacement, spark plug inspection, brake checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault finding charts. Major Repairs: Engine rebuilds, transmission overhaul, suspension component replacement, carburetor rebuilding. Component Overhaul: Detailed steps for dismantling, cleaning, inspecting, and reassembling key components. Torque Specifications: Precise torque values for all critical fasteners. Wiring Diagrams: Comprehensive electrical system schematics for easy diagnosis and repair. Special Tool Identification: Identification of necessary special tools required for specific procedures. Technical Depth Depth: Comprehensive (From basic rider maintenance to full engine and chassis rebuilds) Diagnostic Capability: Advanced diagnostic procedures and troubleshooting guides. Illustrations: Step-by-step illustrations and diagrams for clarity. 📊 Manual Specifications File Format Format: PDF Compatibility: PC, MAC, Tablets, Smartphones Required Software: Adobe Reader (Free Download) Print Quality Quality: High Quality (Printable) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, DOHC, Single-cylinder Displacement: 249 cc (249 cubic centimeters) Bore X Stroke: 72.0 x 61.2 mm Cooling System: Liquid-cooled Performance Horsepower Estimated: Approximately 25-30 HP (Varies by market and specific model year tune) Torque Estimated: Approximately 20-23 Nm (Varies by market and specific model year tune) Fuel System Fuel Delivery: Carburetor (e.g., Keihin CVK34 or similar for most models in this range) Fuel Type: Unleaded Gasoline Ignition System Ignition: Digital CDI with electronic advance Starting System Starter: Electric Start (standard on most models, kick start backup may be present on some early models) 🔧 Transmission Standard Type: 6-speed constant mesh Optional Optional Transmissions: N/A (Manual transmission only for this model line) Features Clutch: Wet, multi-disc, manual operation Final Drive: Chain Drive 📐 Dimensions Exterior Length Overall: Approx. 2,165 mm (85.2 in) for KLX250R, may vary slightly for D-Tracker. Width Overall: Approx. 800 mm (31.5 in) for KLX250R, may vary slightly for D-Tracker. Height Overall: Approx. 1,190 mm (46.9 in) for KLX250R, may vary slightly for D-Tracker. Wheelbase: Approx. 1,430 mm (56.3 in) Weights Dry Weight: Approx. 127 kg (280 lbs) for KLX250R, may vary slightly for D-Tracker. Curb Weight: Approx. 136 kg (300 lbs) for KLX250R (with all fluids and ready to ride), may vary. Fuel Capacity: Approx. 10 Liters (2.6 US gal) 🛡️ Safety Features Ratings Safety Standards: Meets applicable national/international safety and emissions standards for its class and era. Active Features Brakes: Disc brakes front and rear (specific configurations may vary slightly, D-Tracker typically has dual front discs on later models). Lighting: Headlight, taillight, brake lights, turn signals. Passive Features Frame Design: Perimeter frame for rigidity and stability. Ergonomics: Designed for rider control and comfort...