This workshop service manual covers the first generation KLX250R models from 1993 to 1997. The KLX250R is a capable dual-sport motorcycle, recognized for its robust engineering and versatility in both off-road and street riding. There is a long history in off-road motorcycling, and this model represents a significant part of that heritage, offering riders a reliable platform for adventure and exploration. Its liquid-cooled, four-stroke, single-cylinder engine, coupled with a 6-speed transmission and capable suspension, makes it a popular choice for enthusiasts seeking performance and durability. This comprehensive English-language manual provides detailed information for maintaining and repairing the KLX250R. It covers all major systems, including engine disassembly and assembly, fuel and ignition systems, transmission, electrical components, and chassis elements such as suspension and brakes. The manual includes step-by-step repair instructions, routine maintenance procedures, troubleshooting guides, and essential technical specifications, all presented with clarity using warning, caution, and note symbols to highlight critical information. Its depth of coverage is suitable for professional technicians and experienced owners, enabling efficient and accurate service. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250R Generation: First Generation Codes Model Years Covered: 1993, 1994, 1995, 1996, 1997 👋 Introduction Market Position Target Audience: Mechanical technicians and experienced motorcycle owners performing maintenance and repairs Competitive Analysis Value Proposition: Provides dealership-level technical information, enabling cost savings and quality service Key Features Accuracy: Endeavored accuracy and reliability of information Completeness: Comprehensive instructions for most repairs Clarity: Emphasis on specific information using WARNING, CAUTION, NOTE symbols Practicality: Enables owners to perform a wide range of maintenance and repairs, saving time and money. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Language: English Page Count Page Count: 299 Format File Format: PDF Delivery Method: Electronic Delivery via Email Printable: Yes 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly and assembly, lubrication system, fuel system, exhaust system, ignition system, cooling system (if applicable) Transmission Systems: Transmission disassembly and assembly, clutch operation, gear shifting mechanisms Electrical Systems: Wiring diagrams, lighting, battery, charging system, ignition system components, starter system Bodywork And Chassis: Frame, suspension (front and rear), wheels, tires, brakes, handlebars, controls, body panels, seat Cooling System: Radiator, hoses, thermostat, coolant level checks and flushing procedures Frame And Body: Frame inspection, swingarm lubrication and adjustment, fairing and plastic panel removal/installation Carburetor Overhaul: Detailed instructions for cleaning, adjusting, and rebuilding the carburetor. Procedures Included Routine Maintenance: Tune-ups, oil changes, filter replacements, chain adjustments, lubrication, general inspections Diagnostic Procedures: Troubleshooting guides for common issues, symptom-based diagnostics Repair And Overhaul: Detailed step-by-step instructions for component removal, repair, and reinstallation Component Specific Instructions: Instructions for proprietary components with emphasis on manufacturer recommendations Suspension Adjustment: Instructions for adjusting front forks (preload, compression, rebound) and rear shock (preload, rebound damping) Wheel And Tire Service: Tire pressure checks, wheel removal/installation, spoke tension adjustment (if applicable) Wiring Diagram Interpretation: Detailed wiring diagrams for all electrical systems Troubleshooting Guides: Specific troubleshooting trees for various performance issues (e.g., starting problems, poor acceleration, misfiring). Technical Depth Depth Of Coverage: Comprehensive, suitable for professional technicians and knowledgeable DIY mechanics, covering routine to complex repairs Special Tools: Identification and usage instructions for specialized Kawasaki tools Safety Information: Emphasis on safety precautions, warnings, and cautions Engine Rebuild: Comprehensive procedures for engine disassembly, inspection, measurement, and reassembly, including piston, rings, and cylinder work. 📊 Manual Specifications File Format PDF Quality: High-resolution scans/digital creation, enabling clear text and image reproduction Searchable Text: Likely includes searchable text for efficient information retrieval. Print Quality Printability: Designed for clear printing of all 299 pages Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Technical Depth Diagnostic Codes: Manual may include information on interpreting diagnostic codes if the model is equipped with basic electronic fault indicators. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, single-cylinder Performance Displacement: 249cc Fuel System Carburetion: Mikuni VM34 (typical for this era, manual will confirm specifics) Fuel Type: Unleaded gasoline (manual will specify octane rating) Lubrication System Oil Type: Motorcycle-specific 4-stroke engine oil (manual will specify viscosity and API classification) Engine Components Valve Actuation: DOHC (Double Overhead Camshaft) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet, multi-disc Transmission Fluid Fluid Type: Motorcycle-specific transmission oil or engine oil (manual will specify) 📐 Dimensions Weights Dry Weight: Approximately 120-125 kg (265-275 lbs) - typical for model, manual will have exact figure Wet Weight: Approximately 130-135 kg (287-298 lbs) - typical for model, manual will have exact figure Fuel Capacity: Typically around 10-12 liters (2.6-3.2 US gal) Exterior Ground Clearance: Varies by suspension setting, typically around 300mm (11.8 inches) Seat Height: Approximately 890-910mm (35-35.8 inches) 🛡️ Safety Features Active Features Braking System Front: Disc brake (single or dual, manual will confirm) Braking System Rear: Disc brake Passive Features Lighting System: Headlight, tail light, brake light, turn signals (manual details electrical...