Introduction
This service manual provides comprehensive service, repair, and maintenance information for the Kawasaki KLR250 dual sport motorcycle, produced from 1984 to 2005. The KLR250 is a lightweight dual-sport motorcycle featuring a 249cc, single-cylinder, four-stroke engine. It is recognized for its reliability, fuel efficiency, and versatility for both on-road and off-road use. The manual, published by Cyclepedia Press LLC, contains 413 pages of detailed instructions to assist owners in maintaining their motorcycle.
Figure 1: Front cover of the Kawasaki KLR250 KL250 Service Manual.
Figure 2: Back cover of the Kawasaki KLR250 KL250 Service Manual, displaying ISBN and barcode.
Model Coverage
- 1984 KL250-C2
- 1985 KL250-D2
- 1986 KL250-D3
- 1987 KL250-D4
- 1988 KL250-D5
- 1989 KL250-D6
- 1990 KL250-D7
- 1991 KL250-D8
- 1992 KL250-D9
- 1993 KL250-D10
- 1994 KL250-D11
- 1995 KL250-D12
- 1996 KL250-D13
- 1997 KL250-D14
- 1998 KL250-D15
- 1999 KL250-D16
- 2000 KL250-D17
- 2001 KL250-D18
- 2002 KL250-D19
- 2003 KL250-D20
- 2004 KL250-D21
- 2005 KL250-D22
Quick Reference
- Specifications
- Torque Specifications
- VIN and Engine Number Locations
Periodic Maintenance
- Periodic Maintenance Chart
- Air Filter Servicing
- Bolts, Nuts, and Fasteners Inspection
- Brake Fluid Level Check
- Brake System Inspection
- Choke Cable Adjustment
- Cooling System Inspection
- Clutch System Inspection
- Compression Check
- Drive Chain Adjustment
- Engine Idle Speed Adjustment
- Engine Oil Change
- Fuel Line Inspection
- General Lubrication Points
- Spark Arrestor Cleaning
- Spark Plug Inspection and Replacement
- Steering Inspection
- Suspension Inspection
- Throttle Free Play Adjustment
- Tire Inspection and Pressure Check
- Valve Adjustment
External Components
- Engine Guard
- Exhaust System
- Headlight Cover
- Footpegs
- Front Fender
- Fuel Tank
- Handlebar
- Kickstand
- Radiator Shrouds
- Rear Fender
- Seat
- Side Covers
- Sub-Frame
Cooling System
- Coolant
- Coolant Reservoir Tank
- Radiators and Fan
- Thermostat
- Water Pump
Fuel System
- Airbox
- Carburetor Removal and Installation
- Carburetor Overhaul
- Fuel Level Inspection
- Petcock and Fuel Strainer
- Emissions System
Engine
- Cylinder Head Cover
- Camshafts and Rocker Arms
- Cylinder Head
- Valves
- Valve Lapping
- Valve Guide Replacement
- Piston and Cylinder
- Clutch Removal
- Clutch Installation
- Alternator
- Gearshift Mechanism
- Kick Starter
- Oil Pump
- Primary Drive Gear
- Engine Removal
- Engine Installation
- Crankcases
- Balancer Removal
- Balancer Installation
- Crankshaft
- Crankcase Bearings
- Transmission
- Transmission Shafts
Final Drive
- Chain
- Engine Sprocket
- Rear Sprocket
Steering
- Steering Bearing Service
Front Suspension
- Fork Removal and Installation
- Fork Oil Change
- Fork Disassembly
- Fork Assembly
Rear Suspension
- Rear Shock Absorber
- Swing Arm
- Linkage
Brakes
- Front Disc Brake System
- Front Caliper Service
- Front Master Cylinder Service
- Rear Drum Brake System
- Rear Brake Pedal and Rod Adjustment
Wheels
- Front Wheel Service
- Rear Wheel Service
- Wheel Inspection
- Wheel Bearing Replacement
Electrical Systems
- Battery
- Charging System
- Ignition System
- Horn
- Instrument Cluster
- Fuse and Diode
- Relays
- Switches
- Headlight
- Taillights
- Turn Signals
- Color Wiring Diagrams
Additional Information
Historically, servicing the KLR250 often required using the Kawasaki Factory Service Manual for the KLR600, with a separate supplement for KLR250-specific information. This manual consolidates all necessary information into a single volume for convenience.
Warranty and Support
Information regarding product warranty or direct technical support for this service manual is not provided within the product description. For inquiries, please refer to the publisher, Cyclepedia Press LLC, or the retailer where the manual was purchased.
