1984-2005 Kawasaki KLR250 Motorcycle Service Manual Supplement

Comprehensive repair documentation for the Kawasaki KLR250, covering all systems and components. Includes detailed procedures and specifications. Part number 99924-1051-01.

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Document Details

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Document Number / Seller:
26227 / Linda Diaz
File Size:
36.66 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Oct 24, 2025

Models Covered & Key Technical Specifications

Kawasaki KLR250 (99924-1051-01) – 1984-2005 KLR 250 & Kawasaki Motorcycle & Engine Company. • Nominal System Volume: 11.5 L capacity ensures adequate fuel supply for operation. • Principal Spacing Data: 2-3 mm throttle grip free play is essential for smooth throttle operation. • Rated Wattage Specs: The electrical system operates on 12V AC, rated at 10.5 A @ 8,000 r/min. • Technical Cold Start Limits: Ignition timing is set to 10 • Standard Form Factor: Overall length measures 2,240 mm for optimal maneuverability. • Design Liquid Volume: 2.0 L of SAE 10W40 viscosity oil is required for proper lubrication.

Professional Workshop Service Manual & Technical Specifications

Reference-Grade Procedure Training Manual: Kawasaki KLR250 manual. 1984-2005 edition. Knowledge-Base

Service-Level: KLR250 // Repair-Classification: Motorcycle / Engine Logic // Service-Level: N/A.

Service-Nexus Technical-Path Framework
General Information Procedures Maintenance
Fuel System Carburetion Component Data
Engine Top End Valve Train Specifications
Electrical System Wiring Diagrams
Periodic Maintenance Chart Intervals Schedules

Cataloging major assemblies into functional groups, this manual provides a methodical approach to servicing. Strategically requiring insight into the KLR250's mechanical makeup, it details component removal, installation, and adjustment. The document includes a thorough overview of systems, from the fuel delivery and electrical circuits to the engine's internal workings.

General Information

This section details pre-service checks, model identification, and general specifications for the KLR250.

Fuel System

It covers carburetor specifications, adjustments, disassembly, and installation, along with fuel tank and air cleaner maintenance.

Engine Top End

This part documents the engine's top-end components, including valve train specifications, cylinder head, piston, and muffler procedures.

Electrical System

Provides detailed information on the KLR250's electrical system, including battery, lighting, ignition, and wiring diagrams.

Periodic Maintenance Chart

Outlines recommended service intervals and checks to ensure optimal performance and longevity.

FAQ

Check the **standard** idle speed setting. keyboard_arrow_down

1,300 r/min is the standard idle speed for the carburetor, ensuring smooth operation.

What does the **necessary** valve clearance adjustment procedure involve? keyboard_arrow_down

0.10 - 0.20 mm for inlet and 0.15 - 0.25 mm for exhaust are the specified valve clearances that need adjustment.

Reference the **recommended** coolant level for the motorcycle. keyboard_arrow_down

Between the FULL and LOW marks on the reserve tank cover is the recommended coolant level.

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Reviews (3)

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The service manual covers everything you need to know. I had a question about the cooling system, and support responded quickly and professionally. Great service!
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This manual has been invaluable for my bike maintenance. The download was smooth, and I appreciated the prompt email support when I had queries. Worth every penny!
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New
This manual is a lifesaver for anyone working on a KLR250. The download process was seamless, and I received my link almost instantly. Highly recommend!