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

Diagnostic procedures and component service for Kawasaki KLX250/D-Tracker KLX 250R models. Documents paper handling and control panel diagnostics. PN 56019-120

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Document Details

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Document Number / Seller:
26322 / Kenneth Clark
File Size:
13.49 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Feb 2, 2025

Models Covered & Key Technical Specifications

1993-1997 Kawasaki KLX250 / D-Tracker KLX 250R (56019-120) – Motorcycle

Service Manual | Series Documentation.

  • Prescribed Ambient Limits: 0.5 mm establishes the standard for valve clearance for the inlet portion of the engine.
  • Documented Cycle Rate: For optimal operation, 21 clicks defines the standard compression damping adjustment setting.
  • Core Size Parameters: 43 mm signifies the standard inner tube diameter for the front fork assembly.
  • Rated Fastening Values: 88 N-m -- signifies the standard torque for the swingarm pivot shaft nut.
  • Technical Charge Quantity: The standard oil capacity for the front fork is 540 mL for upside down forks.
  • Advanced Heat Tolerance: 175 kPa establishes the standard rear tire pressure for KLX250E models when loaded.

Professional Workshop Service Manual & Technical Specifications

Detailed Troubleshooting Operator's Manual: Kawasaki KLX250, KLX 250R repair manual (´93-´97) Procedure-Library

Technical-Domain: KLX250, KLX 250R / Model-Specs: 1993-1997 / Technical-Domain: Motorcycle

Integrated-Framework System-Path Architecture
Engine Top End Valves Clearance Inspection
Crankshaft / Transmission Crankcase Splitting
Fuel System Carburetor Idle Speed Inspection
Wheels/Tires Tires Air Pressure Inspection/Adjustment
Brakes Caliper Front Caliper Removal

Maintenance hierarchies are structured into several key areas, documenting procedures for engine and chassis systems. This manual provides essential information on component specifications, disassembly, assembly, and inspection to ensure proper maintenance and repair. The document details critical torque specifications for various fasteners, ensuring axial load stability and correct component function. Key systems covered include the fuel system, cooling system, engine lubrication, drivetrain components, suspension, brakes, and electrical systems. The manual also includes procedures for wheel and tire maintenance, final drive systems, and engine removal/installation, offering a comprehensive resource for service. Reliably requiring precise specifications, this manual details the necessary adjustments and component replacements for optimal performance. Maintenance procedures are specified for engine oil and filters, ensuring consistent lubrication and engine longevity. Component locations are identified for critical parts such as the clutch and brakes. Service intervals are documented for regular maintenance, including chain lubrication and tire pressure checks. Calibration requirements are specified for systems like the front fork's compression damping.

FAQ

What are the **proper** clearance measurements for the valve adjustment? keyboard_arrow_down

0.10-0.19 mm for the inlet valve and 0.15-0.24 mm for the exhaust valve are the standard measurements when the engine is cold.

Specify the **standard** torque specifications for the cylinder head bolts. keyboard_arrow_down

8 mm Allen cylinder head bolts require 15 N-m for initial tightening and 46 N-m for final tightening, while 6 mm bolts require 12 N-m.

What is the **necessary** procedure for brake fluid bleeding? keyboard_arrow_down

After attaching a hose to the caliper bleed valve, pump the brake lever, open and close the bleed valve, release the lever, and repeat until no air bubbles are visible.

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Reviews (3)

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This service manual is a must-have for any KLX250 owner! It covers everything in detail. The download process was smooth and I received the link in my email instantly.
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The manual is very comprehensive and well-organized. Downloading it was a breeze, and the email with the link arrived promptly. Very satisfied!
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I found this manual incredibly helpful for maintenance and repairs. The customer support was quick to respond when I had questions. Highly recommend!