• 2

  Quick Reference Guide
• 4

  List of Abbreviations
• 4

  Safety Instructions
• 7

  Foreword
• 9

  General Information
• 9

  Table of Contents
• 10

  Before Servicing
• 12

  Model Identification
• 12

  KL250-D2 Left Side View: U.S. Model
• 12

  KL250-D2 Right Side View: European Model
• 13

  General Specifications
• 16

  Periodic Maintenance Chart
• 17

  Fuel System
• 18

  Exploded Views
• 20

  Fuel System Specifications
• 20

  Special Tool
• 21

  Throttle Grip Play Inspection
• 21

  Throttle Cable Adjustment
• 21

  Throttle Cable Lubrication
• 22

  Throttle Cable Inspection
• 22

  Choke Cable Free Play Inspection
• 22

  Choke Cable Adjustment
• 22

  Choke Cable Lubrication
• 23

  Element Installation
• 23

  Evaporative Emission Control System
• 24

  Cooling System
• 26

  Cooling System Specifications
• 27

  Coolant Changing
• 27

  Water Pump Removal
• 27

  Mechanical Seal Removal
• 27

  Impeller Installation
• 28

  Engine Top End
• 31

  Engine Top End Specifications
• 34

  Chain Tensioner Installation
• 34

  Camshaft Removal Notes
• 34

  Camshaft Installation Notes
• 34

  Camshaft Chain Timing (Lefthand View)
• 35

  Camshaft Cap Installation
• 35

  Camshaft Bearing Oil Clearance Inspection
• 35

  Rocker Arms, and Rocker Shaft Removal
• 35

  Rocker Arms and Rocker Shaft Installation Notes
• 36

  Rocker Arms and Rocker Shaft Inspection Note
• 36

  KACR Inspection
• 36

  Compression Measurement
• 36

  Cylinder Head Removal
• 37

  Cylinder Head Bolts, Nuts Tightening Sequence
• 37

  Cylinder Head Disassembly Note
• 37

  Valve Clearance Inspection
• 37

  Valve Clearance Adjustment
• 38

  Valve Seat Inspection
• 38

  Cylinder Removal
• 38

  Piston Removal Notes
• 38

  Piston, Cylinder Installation Note
• 39

  Piston Ring Openings
• 39

  Piston Ring End Gap
• 39

  Cylinder Inside Diameter
• 39

  Piston Diameter
• 40

  Muffler Cleaning (U.S. Model)
• 40

  Spark Arrester Cleaning (U.S. Model)
• 41

  Engine Right Side/Left Side
• 43

  Engine Right Side Specifications
• 44

  Right Engine Cover Removal
• 44

  Right Engine Cover Installation Notes
• 44

  Clutch Lever Play Adjustment
• 45

  Clutch Release Lever Removal
• 45

  Clutch Release Lever Installation Notes
• 45

  Clutch Removal
• 46

  Friction Plate Installation
• 46

  Friction Plate Wear, Damage Inspection
• 46

  Friction and Steel Plate Warp Inspection
• 47

  External Shift Mechanism Removal
• 47

  External Shift Mechanism Installation Note
• 47

  External Shift Mechanism Inspection
• 47

  Primary Gear Removal
• 48

  Primary Gear Installation Note
• 48

  Kick Starter Removal
• 48

  Kick Starter Disassembly and Assembly Note
• 48

  Kick Starter Idle Gear Removal and Installation Notes
• 49

  Engine Lubrication System
• 51

  Engine Lubrication System Specifications
• 52

  Engine Oil Change
• 52

  Oil Pressure Measurement
• 52

  Oil Filter Removal and Installation Note
• 53

  0Il Pump Removal
• 53

  0Il Pump Installation Note
• 53

  0Il Pump Disassembly
• 53

  0Il Pump Assembly Note
• 54

  Engine Removal/lnstallation
• 56

  Engine Removal
• 56

  Engine Installation
• 57

  Crankshaft/Transmission
• 60

  Crankshaft/Transmission Specifications
• 61

  Crankcase Splitting
• 61

  Crankcase Assembly
• 61

  Output Oil Seal, Ball Bearing Installation
• 61

  Shift Rod and Shift Fork
• 62

  Transmission Removal
• 62

  Drive Shaft, Output Shaft
• 63

  Transmission Installation Notes
• 63

  Crankshaft Removal
• 63

  Crankshaft Installation Notes
• 64

  Crankshaft Disassembly and Assembly
• 64

  Front Right Side Balancer Removal
• 64

  Front Right Side Balancer Installation
• 64

  Crankshaft Maintenance
• 65

  Front Left Side Balancer, Balancer Chain Removal
• 65

  Front Left Side Balancer, Balancer Chain Installation (Including Chain Timing Procedure)
• 66

  Chain Guides
• 66

  Balancer Sprocket Removal Note
• 66

  Balancer Sprocket Installation Note
• 67

  Balancer Chain Timing
• 68

  Wheels/Tires
• 70

  Wheels/Тіres Specification
• 71

  Front Wheel Removal
• 71

  Rear Wheel Removal
• 71

  Axle Inspection
• 71

  Tire Air Pressure Measurement
• 72

  Tire Air Pressure (When Cold)
• 72

  Tire Wear Inspection
• 72

  Tire Removal and Installation
• 72

  Wheel Bearing Installation Note
• 74

  Final Drive
• 76

  Final Drive Specifications
• 77

  Drive Chain Slack Inspection
• 77

  Drive Chain Slack Adjustment
• 77

  Drive Chain Removal
• 78

  Drive Chain Installation
• 78

  Engine Sprocket Removal
• 78

  Rear Sprocket, Coupling Installation
• 78

  Sprocket Wear
• 79

  Sprocket Warp
• 79

  Coupling Bearing Removal
• 79

  Coupling Bearing Installation
• 79

  Coupling Bearing Inspection and Lubrication
• 80

  Grease Seal Inspection and Lubrication
• 80

  Damper Inspection
• 81

  Brakes
• 83

  Brakes Specifications
• 84

  Disc Wear
• 84

  Disc Cleaning
• 84

  Disc Runout
• 84

  Brake Drum Wear
• 86

  Suspension
• 88

  Suspension Specifications
• 89

  Air Pressure Adjustment
• 89

  Fork Oil Change
• 89

  Front Fork Removal
• 89

  Front Fork Installation
• 90

  Front Fork Disassembly
• 90

  Weight Mounting
• 90

  Front Fork Assembly
• 90

  Guide Bush Installation
• 91

  Rear Shock Absorber
• 91

  Damper Adjustment
• 91

  Spring Preload Adjustment
• 92

  Steering
• 95

  Steering Stem Removal
• 95

  Outer Race Removal
• 95

  Steering Stem Installation
• 95

  Outer Race Installation
• 96

  Torquing Stem Locknut
• 96

  Steering Stem Bearing Lubrication
• 97

  Bearing Wear, Damage
• 97

  Stem Cap (Grease Seal) Deterioration, Damage
• 98

  Frame
• 101

  Rear Frame Removal
• 101

  Rear Frame Installation
• 101

  Suggested Cable or Hose Routing
• 102

  Electrical System
• 106

  Wiring Diagram
• 107

  Electrical System Specifications
• 109

  Battery
• 109

  Electrolyte Level Inspection
• 109

  Battery Condition
• 109

  Hydrometer
• 110

  Battery Initial Charging
• 110

  Battery Ordinary Charging
• 111

  Battery Charging Rate/Тіme Table (12V 4Ah)
• 111

  Battery Test Charging
• 111

  Battery Vent Hose Routing
• 111

  Flywheel Magneto Removal
• 112

  Flywheel Magneto Installation
• 112

  Magneto Cover Installation Note
• 112

  Magneto Stator Installation Note
• 113

  Left Engine Cover Removal
• 113

  Spark Plug Cleaning and Gapping
• 113

  Ignition Timing Inspection (Dynamic)
• 113

  CDI Unit Inspection
• 114

  Wiring Inspection
• 114

  Wiring Routing
• 115

  Appendix
• 116

  Model Application

Kawasaki KLR 250 1998 Motorcycle Photos and Specs. Get the latest Specifications for Kawasaki KLR 250 1998 Motorcycle from mbike.com!

The Kawasaki KLR250/KL250D was a motorcycle produced from 1984 to 2005 as the successor to the 1978 to 1983 KL250C, with only minor changes during the model run. This lightweight dualsport motorcycle was used for several years by the US military for a variety of tasks, including messenger duty and reconnaissance.^{[citation needed]}

• 2Specifications

Development & Design[edit]

It was produced by Kawasaki Heavy Industries in Japan and exported to many parts of the world, including the U.S. and Canada, Europe and Australia. The Chilean national police ('Carabineros de Chile') made extensive use of the KLR250. It is similar in appearance to the larger KLR650. The KLR250 shares many engine parts with an ATV sold by Kawasaki, the KSF250 'Mojave'.

In the USA the KLR250 was discontinued at the end of the 2005 model run and was replaced by the KLX250S in 2006.In other markets the KLX250 was introduced in 2001 and has been sold to the current day.

Specifications[edit]

The base specifications have remained virtually unchanged throughout the production period.

Engine[edit]

• Type: Four-stroke, DOHC, four-valve, single cylinder
• Displacement: 249 cc
• Bore and Stroke: 74.0 x 58.0 mm
• Carburetor: Keihin CVK34
• Compression ratio: 11.0:1
• Power Output:

28 horsepower 1985–1989

23 horsepower 1990–2005 @ 9,000 rpm, (U.S. model due to change in cam profile)

• Maximum torque: 23 N-m (2.3 kg-m, 16.5 ft-lb) @ 8,000 rpm (U.S. model) ^[1]
• Starting Method: Kick

Drivetrain[edit]

• Transmission: 6 Speed
• Final Drive: Chain EK520 L-O 104 links

Brakes[edit]

• Front: Hydraulic disc
• Rear: Drum

Suspension[edit]

• Front: Air-adjustable hydraulic telescopic fork
• Rear: UNI-TRAK single-shock system

Wheels and tires[edit]

• Front: 3.00 x 21 tire
• Rear: 4.60 x 17 tire

1998 Kawasaki Klr 250 Manual Pdf

Dimensions[edit]

• Length: 84.3 in
• Seat height: 33.7 in
• Rake and Trail: 28.5 degrees / 4.6 in
• Wheelbase: 55.7 in
• Weight: 258 lb (117 kg) dry
• Fuel Capacity: 2.9 US gal (11.0 litres)
• Engine oil capacity: 2 liters

Fuel Efficiency[edit]

• 65 miles per U.S. gallon (est)
• Maximum range: 188.5 U.S. miles

References[edit]

1995 Kawasaki Klx 250

1. ^Kawasaki KLR 250 Service Manual, 14th Edition. 2004. Part No. 99924-1051-14.

Kawasaki Klr 250 Specifications