Kawasaki KLX250 Maintenance and Repair Manual

The kawasaki manual covers all repair and maintenance procedures. It's simple to use, full of in depth information and specifically written for the kawasaki klx250 motorcycle. Having simple to follow illustrations/diagrams and instructions makes it so much easier, no matter how complex the repair.

Even if you’ve never done any motorcycle maintenance or repair before, you’ll find all the information you need to get started. Professional mechanics and master technicians also use this manual.

Make and Model Year Language Price Rating Instant Download
Kawasaki KLX250 (D, E) (R) 1993-1997 £9.99

Supplied in easy to read and print pdf format and works with all operating systems; Windows XP, Vista, 7, MAC, etc. (any device that reads pdf format) plus there's No waiting for delivery!

Example Contents

General Info & Maintenance Fuel & Cooling System
Engine, Clutch & Transmission Electrical System
  • Clutch hoses & pipe replacement
  • Model identifications
  • Brake maintenance
  • Engine valve clearance
  • Drive train lubrication, adjustment & wear
  • Fuel hoses
  • Air pressure & tyre damage & wear
  • Using the workshop manual
  • Before servicing
  • General specifications
  • Spark plug replacement
  • Wheel & tyre
  • Clutch fluid change
  • Fuel system
  • Lubrication of parts
  • Suspension, fork oil
  • Maintenance
  • Unit conversion table
  • Engine type
  • Wheel bearings
  • Dimensions
  • Electrical system
  • Shock absorber oil
  • Emission control information
  • Steering system
  • Technical information
  • Air cleaner
  • Brake fluid
  • Cooling system
  • Torque settings, special tools & specifications
  • Periodic maintenance chart
  • Steering stem bearing lubrication
  • Coolant change
  • Engine oil & oil filter
Wheels & Tyres

  • Balancing
  • Axle
  • Hub bearing
  • Specification & service Information
  • Tyres
  • Tyre pressure
  • Exploded view
  • Front wheel
  • Rear wheel

  • Sub throttle valve actuator
  • Self diagnosis
  • Fuel Injectors
  • Sub throttle sensor
  • Fuel line
  • Radiator cap
  • ECU main relay
  • Fuel tank
  • Speed sensor
  • Crankshaft sensor
  • Water pump
  • Camshaft position sensor
  • Warning Indicator light
  • Water temperature sensor
  • Inlet air temperature sensor
  • Vehicle down sensor
  • DFI power source
  • Exploded view
  • Coolant
  • Pressure testing
  • ECU
  • Fuel pump
  • Gear position switch
  • DFI system
  • Main throttle sensor
  • Blank key detection
  • Fuel pump relay
  • Troubleshooting
  • Immobilizer amplifier
  • Throttle body
  • Stick coils
  • Air line
  • Thermostat
  • Water temperature sensor
  • Throttle grip & cables
  • Atmospheric pressure sensor
  • Hoses & pipes
  • Radiator
  • Evaporative emission control system
  • Coolant flow chart
Brakes & Steering
  • Steering stem
  • Brake fluid
  • ABS anti-lock braking system
  • Brake hoses
  • Brake lever & brake pedal
  • Brake disc & brake pads
  • Calipers
  • Steering Inspection & adjustment
  • Exploded view, service Information
  • Master cylinder

  • Transmission shaft
  • Exhaust system
  • Hoses
  • Connecting rod big end bearing
  • Clean air system
  • Clutch fluid
  • Cylinder head & cylinder head cover
  • Engine Removal & Installation
  • Oil cooler
  • Compression measurement
  • Starter motor clutch & torque limiter
  • Crankcase splitting
  • Oil pan
  • Muffler, exhaust pipe
  • Bleeding the clutch
  • Oil pressure switch
  • Clutch & clutch cover
  • Valves
  • Engine Lubrication System
  • Oil pressure switch
  • Clutch plate
  • Crankshaft main bearing
  • Crank pin
  • Shift pedal
  • Clutch master cylinder
  • Camshaft chain tensioner
  • Oil pressure measurement
  • Transmission & crankshaft
  • Piston & piston ring
  • Balancer
  • Exploded view, specifications, special tools & sealant
  • Oil pump
  • Throttle body holder
  • Engine oil & oil filter
  • Transmission
  • Crankshaft & connecting rods
  • Clutch slave cylinder
  • Oil pressure relief valve
  • Shift fork guide, pin & drum
  • Seat cover
  • Center stand
  • Frame
  • Fairing's
  • Seat
  • Fenders
  • Side stand
  • Switches & sensors
  • Tail light/brake light
  • Ignition system
  • Headlight
  • Starter relay
  • Fuses
  • Fuse Inspection
  • Charging
  • Starter motor
  • Battery
  • Fuel level sensor
  • Meter, gauge & Indicator unit
  • IC Igniter
  • Brake light timing
  • Electrical wiring
  • Turn signal lights
  • Electric starter system
  • Regulator
  • Charging voltage
  • Water temperature sensor
  • Lighting system
  • Camshaft position sensor
  • Exploded view & wiring diagram
  • Relay box
  • Immobilizer system
  • Alternator
  • Stick coil
  • ECU
  • Fuel reserve switch
  • Radiator fan system
  • Gear position switch
  • Spark plug
  • Crankshaft sensor
  • Meter unit
  • Air switching valve
Suspension & Final Drive

  • Rebound damper force
  • Rocker arm & tie arm bearing lubrication
  • Swing arm bearing
  • Front fork
  • Rear shock absorber
  • Coupling bearing
  • Front sprocket
  • Chain guard
  • Drive chain
  • Coupling damper
  • Swing arm
  • Wheel alignment
  • Rear sprocket
  • Specifications, service Information & exploded view

The Kawasaki KLX250 is the ideal bike for a novice rider to jump headfirst into the world of off road thanks to its swift, yet manageable 250cc engine. Toting Kawasaki’s renowned lime green paint, the KLX definitely has the style to go with its performance, backed up by aggressive body panels and those nicely oversized mudguards. With its specialist thick tires, the KLX will rip across any uneven terrain as though it was a sports bike on tarmac, but that’s not to say that the KLX only rides well off road. With its dirt-jump-ready extended telescopic suspension, riding on road will be a breeze too.

If you’re into your dirt biking in a big way, it’s expected that you’ll be a little heavy handed with your bike when you’re shredding up the track and even more so if you plan on hitting the jumps. This is why dirt bikes in general are more susceptible to being damaged mid-use. Pushing your KLX to its limits on a regular basis can really take its toll on the condition of the working parts within the bike, which is why it’s vital to get your bike booked in for a service regularly. Now, the problem that presents itself here is the cost involved with these services.

Garages can often charge extortionate amounts for the smallest of maintenance tasks, purely because of the cost of employing the mechanic to carry out the work. So how can you remedy this? Well, the answer comes in the form of the manual and, as you may have guessed, it involves carrying out the motorcycle maintenance yourself. No specialist skills are necessary thanks to the depth of instruction that the manual offers. All you need to get started is a little motivation and a few tools.

The manual covers everything that you could possibly think of concerning your bike, so if you’ve taken a spill at the jumps or your KLX just won’t start, you’ll have all the answers right in one place. This will inevitably save you a lot of cash in the long run, since you’ll be eliminating all those unnecessary services that can mount up to thousands over the course of a year. You’ll also be ensuring that every single horsepower is being utilised and not slowly disappearing as the bike ages. So why not keep your bike performing as it should with the KLX 250 manual?

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