1984-2005 Kawasaki KLR250 4 Stroke Motorcycle Service & Repair Manual
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Kawasaki KLR250 service manual 1984-2005
This manual is comprised of a base manual for the Kawasaki KLR600, along with a
supplement manual to make it relevant for the KLR250. Kawasaki service manuals
sometimes utilize this build-on-earlier models method when two models are similar to
each other. Use the links below or the bookmarks to the left to get to the manual that
covers your model.
Kawasaki KLR600 base manual
Kawasaki KLR250 supplement manual
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1
Scl %-- Manual
SAFETY AWARENESS
Whenever you see the symbols shown beIow, heed
their instructions!. Always follow safe operating and
maintenance practices.
OThis warning symbol identifies special instructions or
procedur~ which, if not correctIy followd, could
result in personal injury, or loss of life.
OThis caution symbol identifies special instructions or
procedures whlch, if not strictly observed, could result
in damage to or destruction of equipment.
"NOTE"
OThis note symbol indicates points of particular interest
for more efficient and convenient operation.
LIST OF ABBREVIATIONS
Read OWNER'S MANUAL before operating
A arnpere(s)
ABDC after bottom dead center
AC alternating current
ATDC after top dead center
BRDC before bottom dead center
BDC bottom dead center
BTDC before top dead center
"C degree(s) Celcius
DC direct current
F farad (s)
" F degree(s) Fahrenheit
ft foot, feet
9 gram (s)
h hods)
L IiterIs)
Ib pound(s)
m meter (s)
mi n rninute(s)
N newton Is)
Pa pascal (s)
PS horsepower
pound(s) per squarP inch
r revolution
rPm revolution(s) per minute
TDC top dead center
TI R total indicator reading
V volr(s)
W watt 1s)
a ohm(s)
Emission Control Information
To protect the environment in which we all live, Kawasaki has incorporated two emission
control systems in compliance with the applicable regulations of the United States
Environmental Protection Agency.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead,
the vapors are routed through an oil separator to the intake side of the engine. While
the engine is operating, the vapors are drawn into combustion chamber, where they are
burned along with the fuel and air supplied by the carburetors.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the
exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have
been carefully designed and constructed to ensure an efficient engine with low exhaust
pollutant levels.
The Clean Air Act, which is the Federal law covering-motor vehicle pollution, contains
what is commonly referred to as the Act's "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited ...
(3)(A) for any person to remove or render inoperative any device or element of design
installed on or in a motor vehicle or motor vehicle engine in compliance with
regulations under this title prior to its sale and delivery to the ultimate purchaser,
or for any manufacturer or dealer knowing1 y to remove or render inoperative any
such device or element of design after such sale and delivery to the ultimate
purchaser.
(3)(8) for any person engaged in the business of repairing, servicing, selling, leasing, or
trading motor vehicles or motor vehicle engines, or who operates a fleet of motor
vehicles knowingly to remove or render inoperative any device or element of
design installed on or in a motor vehicle or motor vehicle engine in compliance
with regulations under this title following its sale and delivery to the ultimate
purchaser ..."
"NOTE"
o The phrase "remove or render inoperative any device or element of design" has been
generally interpreted as follo ws:
I. Tampering does not include the temporary removal or rendering inoperative of devices
or elements of design in order to perform maintenance.
2. Tampering could include:
a. Maladjustment of vehicle components such that the emission standards are exceeded.
b. Use of replacement parts or accessories which adverse1 y affect the performance or
durability of the motorcycle.
c. Addition of components or accessories that result in the vehicle exceeding the
standards.
d. Permanently removing, disconnectingf or rendering inoperative any component or
el emen t of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF
FEDERAL LAW, THE VIOLATION OF WHICH 1s PUNISHABLE BY CIVIL
PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof:
(1 ) The removal or rendering inoperative by any person other than for purposes of main-
tenance, repair, or replacement, of any device or element of design incorporated into
any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or
element of design has been removed or rendered inoperative by any person.
I
Among those acts presumed to constitute tampering are the acts listed below:
+Replacement of the original exhaust system or muffler with a componerll not in com-
pliance with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s1.
*Removal of the air box or air box cover.
.w
.Modifications to the muffler(s) or air intake system by cutting, drilling, or other means
if such modifications result in increased noise levels.
I
I iQ
Foreword
This manual is designed primarily for use by trained mechanics in a properly equipped shop,
although it cantains enough detail and basic information to make it useful to the motorcycle user who
desires to carry out his own basic maintenance and repair work. Since a certain basic knowledge of
mechanics, the proper use of tools, and workship procedures must be understood in order to carry
out maintenance and repair satisfactorily; the adjustments, maintenance, and repair should be carried
out only by qualified mechanics whenever the owner has insufficient experience, or has doubts as to
his ability to do the work, so that the motorcycle can be operated safely.
In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the
text, thoroughly familiarizing himself with The procedures before starting work, and then do the work
carefully in a clean area. Whenever special tools or equipment is specified, makeshift tools or equip-
ment should not: be used. Precision measuremerrts can only be made i f the proper instruments are
used, and the use of substitute tools may adversely affect safe operation of the motorcycle.
"NOTE"
c Explana tion on major changes and additions, that the unique to later year units since the
of the Service Manual, will be added 'ro the end of the text as "Supplements ".
For the duration of your warranty period, especially, we recommend that all repairs and scheduled
maintenance be performed in accordance with this service manual. Any owner maintenance or repair
procedure not performed in accordance with this manual may void the warranty.
To get the longest life out of your Motorcycle:
Follow the Periodic Maintenance Chart in the General Information Chapter.
.Be alert for problems and non-scheduled maintenance.
.Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are
necessary when servicing Kawasaki motorcycles are listed in the Special Tool Catalog. Genuine parts
provided as spare parts are listed in the Parts Catalog.
.Follow the procedures in this manual carefully. Don't take shortcuts.
.Remember to keep comple.te records of maintenance and repair with dates and any new parts
instal led.
Quick Reference Guide
To use, bend the manual back and
match the desired chapter below against
the black spot showing at the edge of
these pages.
General Information
Fuel System
I
Engine Top End
Cooling System
I
Engine Removal, Installat ion
Engine Bottom End /Transmission
Wheel and Tires
Final Drive
Brakes
Suspension
Controls and Instruments
Frame
L
Electrical System
Appendix
General Information
Table of Contents
....................
Before Servicing 1-2
................. Model Identification 1-4
Specifications ...................... 1-5
................. Bolts Nuts Fasteners 1-8
............... Standard Torque Table 1-8
General Lubrication ................. 1-8
........... Periodic Mahtenance Chart 1 -10
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What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$39.99
The Kawasaki KLR250 4 Stroke Motorcycle 1984-2005 Service & Repair Workshop Manual is a comprehensive resource for all your repair and servicing needs. Whether you are a professional mechanic or a DIY enthusiast, this manual provides detailed instructions and troubleshooting procedures to ensure the correct completion of every job.
Containing hundreds of pages with detailed photos and diagrams, this professional manual is the same type used by professional mechanics and technicians. It includes highly detailed exploded diagrams and pictures to guide you through each step.
With this manual, you have the flexibility to print out a single page or the entire manual, as per your requirement. Additionally, it can be used on multiple computers without any limitations or trial periods, and there is no need for renewal or extra fees.
Compatible with both Windows and MAC computers, this full manual is available for instant access on your computer, tablet, or smartphone. It is a valuable resource that will remain accessible for life, providing you with the support you need for years to come.
