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Kawasaki KLX 250 D-Tracker KLX250R Motorcycle 1993-2007 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX 250 D-Tracker / KLX250R Applicable Years: 1993-2007 Product Type: Service Repair Workshop Manual Download 👋 Introduction Market Position Target Audience: DIY motorcycle owners, independent repair shops, and professional mechanics. Competitive Analysis Manual Advantage: Provides comprehensive, factory-level information often superior to aftermarket manuals. Key Features Visual Aid: Hundreds of pages with detailed photos and diagrams. Instruction Style: Step-by-step instructions for clarity and accuracy. Completeness: Full manual, not a trial or limited version. 📋 Manual Details Coverage Areas Coverage Description: All repairs, servicing, and troubleshooting procedures for Kawasaki KLX 250 D-Tracker and KLX250R motorcycles from 1993 to 2007. Page Count Estimated Page Count: Hundreds of pages (specific number not provided, but described as comprehensive). Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (Implied by product description targeting global market) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Detailed procedures for engine disassembly, assembly, tuning, and overhaul. Fuel System: Carburetor adjustment, cleaning, and rebuilding; fuel tank and line maintenance. Ignition System: Spark plug, ignition coil, CDI unit testing and replacement. Cooling System: Radiator, fan, coolant specifications, and maintenance. Transmission And Drivetrain: Gearbox disassembly, inspection, and repair; clutch operation and maintenance; chain and sprockets. Suspension And Steering: Front fork (USD forks likely), rear shock absorber, linkage, steering head bearing maintenance and adjustment. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, and bleeding. Electrical System: Wiring diagrams, battery, lighting, starter motor, charging system, and electronic component troubleshooting. Chassis And Frame: Frame inspection, swingarm, and wheel bearing service. Bodywork And Plastics: Fairing removal, installation, and repair. Procedures Included Preventative Maintenance: Detailed schedules and procedures for routine checks, oil changes, filter replacements, and lubrication. Troubleshooting: Systematic diagnostic guides for common problems and fault finding. Component Overhaul: Step-by-step instructions for rebuilding major components like the engine, carburetor, and brake systems. Adjustments: Precise instructions for setting valve clearances, carburetor idle, clutch, and brake levers. Torque Specifications: Essential torque values for critical fasteners across all systems. Technical Depth Depth Level: Comprehensive, covering all aspects from basic maintenance to complete engine rebuilds. Diagnostic Capabilities: Includes methods for diagnosing electrical faults and mechanical issues. Special Tools: Identification of any specialized tools required for specific procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Ability: Printable (single pages or entire manual). Binding Type Binding Type: Digital (N/A for printed binding, but implies user prints and binds). Paper Type Paper Type: Digital (N/A for printed paper type, but implies high-resolution for printing). Compatibility Os Compatibility: Compatible with all Windows and MAC computers. Licensing Usage License: Lifetime usage, no expiry dates, usable on multiple devices/computers. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC, single-cylinder (Typical for KLX 250 models of this era). Displacement: Approx. 249 cc (Specific to KLX 250 models, may vary slightly by year/variant). Bore X Stroke: Likely around 72.0 x 61.2 mm (Typical for the 249cc engine). Compression Ratio: Likely around 11.0:1 (Typical for performance-oriented single-cylinders). Performance Horsepower Est: Approximately 25-30 HP (Varies by specific model year and tuning). Torque Est: Approximately 20-23 Nm (Varies by specific model year). Fuel System Fuel Delivery: Carburetor (e.g., Keihin CVK34 for many models, specific variant detailed in manual). Fuel Type: Unleaded gasoline (Regular or Premium depending on manufacturer recommendation). Lubrication Oil Type: Motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 (Specific API classification like SG, SH, SJ or JASO MA recommended in manual). Cooling Cooling Method: Liquid-cooled. 🔧 Transmission Standard Transmission Type: Constant-mesh 6-speed return system. Clutch Type: Wet, multiple-disc, cable-actuated. Features Drivetrain: Sealed chain drive. 📐 Dimensions Exterior Overall Length Est: Approx. 2,155 mm (Varies by specific model year). Overall Width Est: Approx. 800 mm (Varies by specific model year). Overall Height Est: Approx. 1,170 mm (Varies by specific model year). Weights Dry Weight Est: Approx. 110-120 kg (Varies by specific model year and trim). Curb Weight Est: Approx. 125-135 kg (Varies by specific model year and trim). Fuel Tank Capacity Est: Approx. 7.7 - 11.0 Liters (Varies by specific model year). 🛡️ Safety Features Ratings Safety Standards: Meets all relevant Japanese and international motorcycle safety standards for its production era. Active Features Braking System Front: Hydraulic disc brake (Single disc likely on many early models, dual discs on some later variants or D-Tracker specific models). Braking System Rear: Hydraulic disc brake (Single disc). Passive Features Lighting: Headlight, tail light, brake light, turn signals (standard for road-legal models). 💡 Technology Features Infotainment Infotainment Features: Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators. No advanced infotainment systems typical of modern motorcycles. Driver Assistance Driver Assistance Features: N/A (Focus is on mechanical and electrical systems, no electronic rider aids like ABS or traction control on most models of this era). Connectivity Connectivity Options: N/A (No Bluetooth...
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Kawasaki KLX 250 D-Tracker KLX250R Motorcycle 1993-2007 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX 250 D-Tracker / KLX250R
Applicable Years:
1993-2007
Product Type:
Service Repair Workshop Manual Download
👋 Introduction
Market Position
Target Audience:
DIY motorcycle owners, independent repair shops, and professional mechanics.
Competitive Analysis
Manual Advantage:
Provides comprehensive, factory-level information often superior to aftermarket manuals.
Key Features
Visual Aid:
Hundreds of pages with detailed photos and diagrams.
Instruction Style:
Step-by-step instructions for clarity and accuracy.
Completeness:
Full manual, not a trial or limited version.
📋 Manual Details
Coverage Areas
Coverage Description:
All repairs, servicing, and troubleshooting procedures for Kawasaki KLX 250 D-Tracker and KLX250R motorcycles from 1993 to 2007.
Page Count
Estimated Page Count:
Hundreds of pages (specific number not provided, but described as comprehensive).
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English (Implied by product description targeting global market)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Service:
Detailed procedures for engine disassembly, assembly, tuning, and overhaul.
Fuel System:
Carburetor adjustment, cleaning, and rebuilding; fuel tank and line maintenance.
Ignition System:
Spark plug, ignition coil, CDI unit testing and replacement.
Cooling System:
Radiator, fan, coolant specifications, and maintenance.
Transmission And Drivetrain:
Gearbox disassembly, inspection, and repair; clutch operation and maintenance; chain and sprockets.
Suspension And Steering:
Front fork (USD forks likely), rear shock absorber, linkage, steering head bearing maintenance and adjustment.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, and bleeding.
Electrical System:
Wiring diagrams, battery, lighting, starter motor, charging system, and electronic component troubleshooting.
Chassis And Frame:
Frame inspection, swingarm, and wheel bearing service.
Bodywork And Plastics:
Fairing removal, installation, and repair.
Procedures Included
Preventative Maintenance:
Detailed schedules and procedures for routine checks, oil changes, filter replacements, and lubrication.
Troubleshooting:
Systematic diagnostic guides for common problems and fault finding.
Component Overhaul:
Step-by-step instructions for rebuilding major components like the engine, carburetor, and brake systems.
Adjustments:
Precise instructions for setting valve clearances, carburetor idle, clutch, and brake levers.
Torque Specifications:
Essential torque values for critical fasteners across all systems.
Technical Depth
Depth Level:
Comprehensive, covering all aspects from basic maintenance to complete engine rebuilds.
Diagnostic Capabilities:
Includes methods for diagnosing electrical faults and mechanical issues.
Special Tools:
Identification of any specialized tools required for specific procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Ability:
Printable (single pages or entire manual).
Binding Type
Binding Type:
Digital (N/A for printed binding, but implies user prints and binds).
Paper Type
Paper Type:
Digital (N/A for printed paper type, but implies high-resolution for printing).
Compatibility
Os Compatibility:
Compatible with all Windows and MAC computers.
Licensing
Usage License:
Lifetime usage, no expiry dates, usable on multiple devices/computers.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC, single-cylinder (Typical for KLX 250 models of this era).
Displacement:
Approx. 249 cc (Specific to KLX 250 models, may vary slightly by year/variant).
Bore X Stroke:
Likely around 72.0 x 61.2 mm (Typical for the 249cc engine).
Compression Ratio:
Likely around 11.0:1 (Typical for performance-oriented single-cylinders).
Performance
Horsepower Est:
Approximately 25-30 HP (Varies by specific model year and tuning).
Torque Est:
Approximately 20-23 Nm (Varies by specific model year).
Fuel System
Fuel Delivery:
Carburetor (e.g., Keihin CVK34 for many models, specific variant detailed in manual).
Fuel Type:
Unleaded gasoline (Regular or Premium depending on manufacturer recommendation).
Lubrication
Oil Type:
Motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 (Specific API classification like SG, SH, SJ or JASO MA recommended in manual).
Cooling
Cooling Method:
Liquid-cooled.
🔧 Transmission
Standard
Transmission Type:
Constant-mesh 6-speed return system.
Clutch Type:
Wet, multiple-disc, cable-actuated.
Features
Drivetrain:
Sealed chain drive.
📐 Dimensions
Exterior
Overall Length Est:
Approx. 2,155 mm (Varies by specific model year).
Overall Width Est:
Approx. 800 mm (Varies by specific model year).
Overall Height Est:
Approx. 1,170 mm (Varies by specific model year).
Weights
Dry Weight Est:
Approx. 110-120 kg (Varies by specific model year and trim).
Curb Weight Est:
Approx. 125-135 kg (Varies by specific model year and trim).
Fuel Tank Capacity Est:
Approx. 7.7 - 11.0 Liters (Varies by specific model year).
🛡️ Safety Features
Ratings
Safety Standards:
Meets all relevant Japanese and international motorcycle safety standards for its production era.
Active Features
Braking System Front:
Hydraulic disc brake (Single disc likely on many early models, dual discs on some later variants or D-Tracker specific models).
Braking System Rear:
Hydraulic disc brake (Single disc).
Passive Features
Lighting:
Headlight, tail light, brake light, turn signals (standard for road-legal models).
💡 Technology Features
Infotainment
Infotainment Features:
Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators. No advanced infotainment systems typical of modern motorcycles.
Driver Assistance
Driver Assistance Features:
N/A (Focus is on mechanical and electrical systems, no electronic rider aids like ABS or traction control on most models of this era).
Connectivity
Connectivity Options:
N/A (No Bluetooth or smart device integration).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-6,000 km or 6-12 months, as per manual recommendations.
Air Filter Cleaning:
Regular inspection and cleaning/replacement depending on operating conditions (e.g., every 1,000-3,000 km).
Spark Plug Replacement:
Intervals vary, typically 6,000-12,000 km, and checking electrode gap at each service.
Valve Clearance Check:
Typically every 12,000-24,000 km or as specified in the manual.
Fluid Specifications
Coolant Type:
Mixture of ethylene glycol-based antifreeze and distilled water (50/50 mix recommended).
Brake Fluid Type:
DOT 4 (or specified equivalent as per manual).
Known Issues
Carburetor Tuning:
Carburetors can require periodic adjustment or cleaning due to fuel variations or wear. Specific jetting recommendations may be found in the manual for performance upgrades.
Suspension Seals:
Like many motorcycles of this age, fork seals and shock bushings may require replacement due to wear and tear over time.
Cam Chain Tensioner:
Some single-cylinder engines can develop cam chain noise over time, often addressable with a new tensioner or adjustment.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki has a long-standing heritage in motorsports, including motocross and off-road racing, contributing to the KLX line's development.
Model Evolution
Klx Lineage:
The KLX series represents Kawasaki's line of versatile dual-sport and off-road motorcycles, evolving from earlier KX models. The D-Tracker designation often refers to supermoto variants with smaller wheels and street tires.
Production
Manufacturing Region Est:
Primarily Japan, though specific components may be sourced globally.
🏆 Awards & Recognition
Recognitions
Model Reputation:
The KLX 250 series is generally recognized as a reliable and capable dual-sport/supermoto platform, praised for its versatility and off-road prowess.
Ratings
Rider Reviews:
Often positively reviewed for its ease of maintenance, tractable engine, and ability to handle varied terrain. The D-Tracker variant specifically appreciated for its street performance.
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