1993-1997 Kawasaki KLX250 / D-Tracker KLX 250R Service Manual (P/N 56019-120)

• Fits 1993–1997 Kawasaki KLX250 and KLX250R models, covering both D-series and E-series variants for domestic and international markets
• Official OEM publication: PN 56019-120 Third Edition (2), dated July 29, 1997
• Details 17 system chapters, including engine top end, cooling systems, fuel delivery, and electrical architectures
• Outlines precise torque tables for critical fasteners, such as the 88 N-m swingarm pivot shaft and 120 N-m magneto flywheel bolt
• Provides technical parameters for the 249 mL DOHC liquid-cooled engine

Manual Organization and System Coverage

This factory service publication delivers a comprehensive breakdown of major motorcycle systems for professional technicians and DIY mechanics. Chapters are logically divided by function. The document details fuel system components, top-end engine teardowns, and cooling system schematics. It outlines specific component removal, inspection criteria for wear, and assembly protocols for the constant mesh 6-speed transmission and Uni-Trak rear suspension. Always review the general information chapter for model-specific safety procedures and proper shop techniques before beginning any maintenance.

Specification and Reference Data

Finding accurate factory specifications is critical for proper rebuilds and component longevity. This guide provides data for precision adjustments, including standard valve clearance settings (0.10–0.19 mm for the inlet) and exact compression ranges. The reference section lists specific fluid capacities, requiring 1.5 L for engine oil and 540 mL for fork oil. You will also find comprehensive torque specs, such as cylinder head Allen bolts torqued to 46 N-m and spark plugs tightened to 14 N-m. Standard running data, like the 175 kPa rear tire pressure for KLX250E variants, is clearly documented.