This manual covers the KLX300R, a robust off-road motorcycle manufactured between 1993 and 1997. As part of the esteemed KLX lineage, this model is recognized for its strong engine performance and off-road capability, making it a popular choice for enthusiasts and riders seeking reliable trail performance. The first generation KLX300R established a foundation of rugged engineering and dependability, characteristic of a commitment to quality in the off-road segment. This comprehensive workshop service manual provides detailed instructions for the repair and maintenance of your KLX300R. It is designed to assist DIY enthusiasts, independent repair shops, and service technicians by offering dealership-level service information. The manual covers all essential systems, including the engine, transmission, chassis, and electrical components, with step-by-step procedures, diagnostic guidance, and technical specifications. By utilizing this manual, owners and mechanics can effectively maintain, troubleshoot, and repair the motorcycle, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX300R Model Designation: KLX300R Generation Generation Code: First Generation (KLX300) Codes Model Years Covered: 1993, 1994, 1995, 1996, 1997 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, and service technicians seeking detailed repair information. Competitive Analysis Value Proposition: Provides comprehensive, dealership-level service information to enable quality repairs and maintenance, saving time and money compared to professional service. Key Features Completeness: Contains all necessary instructions for any required repair, enabling informed ownership and knowledgeable repairs. Accuracy: Endeavored to ensure the accuracy of information for reliable service. Accessibility: PDF format allows for easy digital access and printing of specific sections. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Repair and Service Page Count Total Pages: 299 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Comprehensive overhaul, diagnosis, tune-ups, lubrication system, cooling system (if applicable), fuel system, exhaust system. Transmission: Removal, installation, overhaul, clutch, gear shifting mechanisms. Chassis: Frame, suspension (front forks, rear shock), steering system, wheels, tires. Electrical System: Ignition system, lighting, battery, wiring diagrams, troubleshooting. Bodywork: Body panel removal/installation, fairings, seat. Procedures Included Maintenance: Routine checks, fluid changes, filter replacements, lubrication, adjustments. Repair: Detailed step-by-step repair procedures for all major components and systems. Overhaul: Complete engine and transmission disassembly and reassembly instructions. Troubleshooting: Diagnostic procedures for common and uncommon faults. Installation: Component removal and installation procedures. Technical Depth Diagnostic Level: Advanced diagnostic procedures, component testing, and symptom analysis. Rebuild Level: Full engine and transmission rebuild procedures, including specifications. Special Tools: Identification and usage of specialized tools required for specific tasks. Torque Specifications: Detailed torque specifications for all critical fasteners. Proprietary Components: Instructions for proprietary components from component manufacturers where applicable. 📊 Manual Specifications File Format Format: PDF Print Quality Printable: Yes Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Delivery Delivery Method: Fast and Free Electronic Delivery via Email ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve Displacement: 292 cc (17.8 cu in) Bore X Stroke: 78.0 x 61.2 mm (3.1 x 2.4 in) Compression Ratio: 10.0:1 Performance Horsepower: Approximately 27-29 hp (varies by year and tuning) Torque: Approximately 18-20 lb-ft (varies by year and tuning) Fuel System Carburetor: Keihin CVK32 Fuel Type: Unleaded gasoline Lubrication System Oil Type: SAE 10W-40 API SG or SH recommended Oil Capacity: Approximately 1.7 L (1.8 US qt) with filter change 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Clutch Type: Wet, multi-disc Features Gear Ratios: Specific gear ratios detailed within the manual. Final Drive: Chain drive 📐 Dimensions Exterior Length: Approximately 2180 mm (85.8 in) Width: Approximately 830 mm (32.7 in) Height: Approximately 1265 mm (49.8 in) Weights Dry Weight: Approximately 117 kg (258 lbs) Fuel Tank Capacity: 10 L (2.6 US gal) 🛡️ Safety Features Ratings Safety Features: While specific safety ratings are not typically applied to off-road motorcycles in the same way as cars, the manual emphasizes safe operating procedures and the use of proper safety equipment. Active Features Braking System: Front: Disc brake; Rear: Disc brake. Details on inspection, adjustment, and replacement are covered. Passive Features Recommended Safety Gear: Helmet, goggles, gloves, protective clothing (as stated in the manual's safety section). 💡 Technology Features Infotainment Infotainment System: N/A (This is an off-road motorcycle from the early 90s, no advanced infotainment systems are present.) Driver Assistance Rider Assistance: N/A (Basic mechanical systems are covered; no electronic rider aids are featured.) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Recommended every 1,000 km (600 miles) or 6 months, whichever comes first (typical for this era). Air Filter Cleaning: Recommended every 500 km (300 miles) or as needed based on operating conditions. Spark Plug Replacement: Recommended every 6,000 km (3,700 miles) or annually. Fluid Specifications Engine Oil: SAE 10W-40, API SG or SH Coolant: If applicable (check specific model year), a permanent type ethylene glycol coolant...