🏷️ Basic Information Identification Make: Kawasaki Model: KLR250 Model Code: KL250-D3 Year: 1986 Codes Engine Code Variant: KL250DE 👋 Introduction Market Position Target User: Do-it-yourself owners and experienced mechanics. Competitive Analysis Value Proposition: Provides professional, dealership-level repair information at a fraction of the cost of professional service. Key Features Usability: Step-by-step instructions and detailed exploded diagrams for efficient and correct repairs. Accessibility: Instant download access, no shipping delays. Portability: Digital format allows for use on smartphones for on-the-trail repairs. 📋 Manual Details Coverage Areas Primary Coverage: 1986 Kawasaki KLR250 KL250-D3 Page Count Estimated Page Count: Refer to specific PDF metadata; typically 300-500 pages for this era of service manual. Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, troubleshooting, diagnostics, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system. Transmission: Clutch operation and adjustment, gear shifting mechanism, internal transmission components inspection and repair. Chassis: Frame, suspension (front forks, rear shock absorber), steering system, wheel bearings, swingarm. Brakes: Front and rear brake systems (disc and drum), hydraulic components, pad/shoe replacement, bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system components, lighting, instrumentation. Fuel System: Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable). Bodywork: Fairing, seat, fuel tank, fenders, side covers, mounting hardware. Procedures Included Maintenance: Routine maintenance checks, oil changes, filter replacements, chain adjustment, brake adjustments, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Systematic diagnosis of common problems, fault finding charts, symptom-based troubleshooting. Repair: Detailed step-by-step instructions for component disassembly, repair, and reassembly. Disassembly Reassembly: Full breakdown and rebuild procedures for all major vehicle systems. Technical Depth Depth: Comprehensive; covers everything from basic adjustments to full engine rebuilds and complex electrical troubleshooting. Diagnostic Tools: Includes specifications for required special tools and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Image Quality: High-quality diagrams and illustrations designed for clarity. Text Clarity: Easy to read text sections. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Recommendation: Printable on standard paper; Adobe PDF Reader recommended for optimal display of images/graphics. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, DOHC, single cylinder Displacement: 249 cc (15.2 cu in) Bore X Stroke: 70.0 x 64.5 mm (2.76 x 2.54 in) Compression Ratio: 9.5:1 Performance Horsepower: Approximately 26-28 hp (varies slightly by region and specific tuning) Torque: Refer to manual for exact figures; typically around 16-18 lb-ft. Fuel System Carburetor: Mikuni VM28SS or similar single carburetor. Fuel Type: Unleaded gasoline (Octane rating specified in manual). Cooling System Cooling Method: Liquid-cooled Lubrication Oil Type: Refer to manual for specific SAE viscosity grade and API classification (e.g., SAE 10W-40 API SG). Oil Capacity: Refer to manual for exact capacity with filter change (typically around 1.7 - 2.0 liters). 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Refer to manual; typically around 2180 mm (85.8 in) Overall Width: Refer to manual; typically around 830 mm (32.7 in) Overall Height: Refer to manual; typically around 1165 mm (45.9 in) Weights Dry Weight: Approximately 136 kg (300 lbs) Curb Weight: Refer to manual; typically around 149 kg (328 lbs) Fuel Tank Capacity: 17 Liters (4.5 US gal) 🛡️ Safety Features Ratings Safety Standards: Adheres to manufacturing standards of its era; manual provides safety precautions for operation and maintenance. Active Features Braking System: Front disc brake, Rear drum brake (for optimal stopping power and modulation). Lighting: Headlight, taillight, brake light, turn signals for visibility. Passive Features Construction: Sturdy frame and bodywork design for rider protection. 💡 Technology Features Infotainment Infotainment Features: N/A (Analog instrumentation: speedometer, odometer, tachometer, indicator lights). 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual; typically every 3,000-5,000 km (1,800-3,000 miles) or annually. Chain Lubrication Adjustment: Frequent checks and lubrication recommended, especially under off-road conditions (every 500-1000 km). Air Filter Cleaning: Recommended every 3,000-6,000 km, depending on operating conditions. Valve Clearance Check: Refer to manual; typically around 6,000-12,000 km or as needed based on performance. Fluid Specifications Coolant Type: Ethylene glycol based antifreeze coolant (50/50 mix with distilled water). Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Known Issues Common Wear Items: Clutch plates, chain and sprockets, fork seals, brake pads/shoes due to age and use. Carburetor Performance: Can be prone to gumming up if fuel sits for extended periods; requires regular cleaning and adjustment. Cooling System: Potential for radiator leaks or thermostat issues over time; proper coolant maintenance is crucial. 📚 Vehicle History Brand Heritage Kawasaki Heritage: Kawasaki Heavy Industries, Ltd. has a long history of producing robust and reliable motorcycles, often with an off-road or dual-sport focus. Model Evolution Klr Lineage: The KLR250 is a predecessor to the highly popular KLR650, establishing a reputation for...