🏷️ Basic Information Identification Make: Kawasaki Model: KLR250 Model Generation: First Generation (KL250-A) Engine Type: 4-Stroke Codes Chassis Code: KL250-A 👋 Introduction Market Position Category: Dual-Sport Motorcycle Target Audience: Riders seeking a reliable and capable motorcycle for on-road commuting and off-road exploration. Competitive Analysis Competitors: Honda XR250L, Yamaha XT250, Suzuki DR250S. Key Features Versatility: Designed for both street use and light off-road trails, a true dual-purpose machine. Durability: Known for its robust and long-lasting engine and chassis, a hallmark of Kawasaki engineering. 📋 Manual Details Coverage Areas Model Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Page Count: Varies by specific release, typically 300-500 pages for comprehensive service manuals. Manual Type Type: Repair Manual / Service Manual / Workshop Manual Language Language: English (presumed, based on common availability for this model) Format Format: Electronic Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage including disassembly, inspection, repair, and reassembly of all engine components. Fuel System: Carburetor service, fuel pump operation, fuel tank, fuel lines, and associated components. Lubrication And Cooling: Oil circulation, oil pump, oil filter, cooling system (air-cooled design details). Transmission Drive Chain: Clutch operation, gearbox disassembly and assembly, chain adjustment and replacement, sprocket maintenance. Steering And Suspension: Handlebar assembly, steering head bearing service, front fork disassembly, inspection, and repair; rear shock absorber maintenance and adjustment. Brakes: Front and rear brake system inspection, service, and repair (likely drum front/rear initially, with disc front introduced later). Electrical System: Ignition system (CDI), lighting circuits, battery maintenance, wiring diagrams, starter motor, alternator. Bodywork And Frame: Body panel removal and installation, frame inspection, seat, fenders, and other cosmetic components. Intake Exhaust: Air filter service, intake manifold, exhaust system inspection and repair. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain lubrication and adjustment, brake adjustments, spark plug service. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common issues. Repair Rebuild: Detailed step-by-step instructions for component disassembly, repair, and reassembly, including engine and transmission overhauls. Specifications: Torque specifications, clearances, fluid types, and capacities for all components. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers everything from basic adjustments to full engine rebuilds. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Quality: Digital PDF; print quality depends on user's printer. Text is typically searchable. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Size: 249cc (249 cm³) Engine Layout: Single-cylinder, four-stroke, DOHC Bore X Stroke: 70.0 mm x 64.5 mm (Typical) Compression Ratio: 9.5:1 (Typical) Performance Horsepower: Approximately 18-20 hp (Varies by year and tuning) Torque: Approximately 13-15 lb-ft (Varies by year and tuning) Fuel System Carburetor: Keihin CVK32 (Typical) Fuel Capacity: Approximately 2.6 gallons (10 Liters) 🔧 Transmission Standard Gearbox: 6-speed constant mesh Optional Transmission Type: Not Applicable (Manual Transmission Only) Features Clutch: Wet, multi-disc Final Drive: Sealed O-ring chain 📐 Dimensions Exterior Length: Approximately 85.6 inches (2175 mm) Width: Approximately 33.5 inches (850 mm) Height: Approximately 46.5 inches (1180 mm) Weights Dry Weight: Approximately 269 lbs (122 kg) Curb Weight: Approximately 289 lbs (131 kg) 🛡️ Safety Features Ratings Crash Test Data: Not Applicable (Motorcycle specific safety ratings are not standardized like automotive). Active Features Braking System: Disc front brake (later models), Drum rear brake (typical). Passive Features Lighting: Headlight, taillight, brake light, turn signals. 💡 Technology Features Infotainment Features: Basic analog instrumentation (speedometer, odometer, tachometer, indicator lights). Driver Assistance Features: Not Applicable (No electronic rider aids typical for this era). Connectivity Features: Not Applicable. 🔧 Maintenance Service Intervals Oil Change: Every 2,000-3,000 miles or 6 months (refer to manual for precise interval). Air Filter Cleaning: Every 2,000-4,000 miles, or more frequently in dusty conditions. Spark Plug Replacement: Every 5,000-7,000 miles (NGK DPR8EA-9 is a common replacement). Fluid Specifications Engine Oil: SAE 10W-40 API SG or higher (e.g., Kawasaki Genuine Oil, Motul 5100). Oil Capacity: Approximately 1.7-1.9 US quarts (1.6-1.8 Liters) with filter change. Fork Oil: Type SS-8 or equivalent SAE 10W (Capacity varies per fork leg, typically ~200-250 ml). Known Issues Common Wear Items: Clutch plates, chain and sprockets, fork seals, carburetor jetting issues due to age/ethanol. Electrical Quirks: Corrosion on connectors, rectifier/regulator failure (less common but possible on older units). 📚 Vehicle History Brand Heritage Manufacturer: Kawasaki Heavy Industries, Motorcycle & Engine Division Model Evolution Introduction Year: 1984 Updates Over Years: Minor updates included front disc brake introduction, revised styling, and occasional suspension refinements. The core design remained consistent. Production Production Span: 1984-2007 (Note: Manual covers up to 2005, but production continued slightly longer). 🏆 Awards & Recognition Recognitions Industry Accolades: While specific awards may not be widely publicized, the KLR250 is recognized for its longevity and reliability as a...