1993-1997 Kawasaki KLX250 / D-Tracker KLX 250R Motorcycle Service Manual

Technical Scope for the 1993–1997 Kawasaki KLX250 and KLX250R

• Fits the 1993–1997 Kawasaki KLX250 and KLX250R motorcycles, covering D-series and E-series variants across domestic and international markets
• Official Kawasaki publication, Third Edition (2) dated July 29, 1997
• Includes 17 detailed system chapters including Engine Top End, Cooling System, Fuel System, and Electrical System
• Delivers precise torque tables for critical fasteners like the 88 N-m swingarm pivot shaft and 120 N-m magneto flywheel bolt
• Stored against your account so you can retrieve it after a hard-drive loss
• Full-text search finds any part number in seconds
• This 1997 edition acts as the definitive service documentation for the 1993–1997 Kawasaki KLX250 and KLX250R model range, providing technical data for the 249 mL DOHC liquid-cooled engine

Manual Organization and System Coverage

This 1993–1997 Kawasaki KLX250 and KLX250R service manual offers a detailed walk-through of major motorcycle systems, facilitating effective maintenance and technical review. Chapters are segmented by function, spanning from general information, including model identification and safety procedures, to deep-dive sections for the fuel system, top-end engine assembly, and cooling system architecture. The document explains specific component removal, inspection for wear or damage, and assembly protocols for the constant mesh 6-speed transmission and the Uni-Trak rear suspension.

Specification and Reference Data

Technical data is provided for precision adjustments, including valve clearance settings and compression ranges. For example, inlet valve clearance is documented at 0.10–0.19 mm, while rear tire pressure for KLX250E variants is 175 kPa. The manual lists fluid capacities, such as 1.5 L for engine oil and 540 mL for fork oil. Additionally, what an OEM service publication covers includes torque specs for the cylinder head allen bolts at 46 N-m and spark plug tightening at 14 N-m. This official 1997 Kawasaki service manual provides exhaustive maintenance and repair specifications for the 1993–1997 Kawasaki KLX250 and KLX250R, covering the engine, fuel, suspension, and electrical systems for the global model range.