Kawasaki KLR250 Dual Sport Cyclepedia Printed Motorcycle Service Manual


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Introducing the Kawasaki KLR250 Motorcycle Service Manual by Cyclepedia Press LLC. Are you ready to unleash the full potential of your Kawasaki KLR250? Look no further than Cyclepedia Press LLC’s service manual, designed to empower you with the knowledge and expertise to conquer any maintenance or repair task. With this printed Cyclepedia manual, you’ll not only receive a wealth of information at your fingertips but also gain access to the full-color online version and technical support for one year, all included with your purchase.

Why buy the Cyclepedia Press LLC manual?

  1. Your Road to Confidence: From routine maintenance procedures to intricate repairs, the Cyclepedia manual covers it all. With the extensive table of contents and intuitive organization, you can easily navigate the information you need. No more guessing or second-guessing – you’ll approach every task with confidence and precision.
  2. Detailed Specifications and Torque Specs: Accuracy is important when it comes to working on your motorcycle. The Cyclepedia manual provides you with quick access to the specifications and torque values you need, ensuring your work is performed to the highest standards.
  3. Periodic Maintenance Made Simple: Never overlook crucial maintenance tasks again. This KLR250 manual includes a comprehensive periodic maintenance chart, guiding you through each step to keep your dual sport motorcycle in top shape. From air filter servicing to brake pad replacement, this manual has got you covered.
  4. Thorough Coverage of External Components: Make removing components easy with step by step instructions and plenty of photos. Whether you’re looking to swap out an exhaust system, replace the seat, or adjust the handlebars, the Cyclepedia manual provides detailed instructions and insights to ensure every modification or repair is a success.
  5. Comprehensive Engine Guidance: Gain a deep understanding of your KLR250’s engine. This manual explores the engine’s inner workings, including top end maintenance, valve adjustment, clutch removal and installation, and clutch and transmission servicing. You’ll become intimately familiar with every component, empowering you to diagnose issues and optimize performance.
  6. Master Your Suspension and Brakes: Don’t overlook the importance of a smooth ride and reliable stopping power. This manual guides you through the intricate processes of front and rear suspension maintenance, fork oil changes, shock absorber inspection, and brake system servicing. Take control of your motorcycle’s handling and safety like never before.
  7. Electrical Systems Demystified: Electrical issues can be frustrating, but the Cyclepedia Press LLC KLR 250 manual simplifies the complexity. This manual delves into every aspect of the electrical system, covering battery maintenance, the charging system, ignition system, lighting, and more. You’ll become a proficient troubleshooter, ensuring your motorcycle’s electrical components always perform flawlessly.
  8. Full Color Wiring Diagrams: Never get lost in a web of wires again. The Cyclepedia Press LLC manual includes detailed, easy-to-follow color wiring diagrams, providing a visual roadmap for your electrical system. Say goodbye to confusion and hello to clarity.

Cyclepedia Press LLC, is committed to providing you with the most comprehensive and user-friendly manual on the market. By investing in the printed repair manual for the Kawasaki KLR250, you’ll gain access to a world of knowledge and support, empowering you to take charge of your motorcycle’s maintenance and repairs.

Embark on a journey of self-reliance. Order your printed copy of the Cyclepedia Press LLC Kawasaki KLR250 Motorcycle Service Manual today. Remember, with your purchase, you receive the printed manual shipped to you in a timely manner, the full-color online version, and dedicated technical support for one year – all included at no extra charge. It’s time to elevate your riding experience to new heights.

Models Coverage
1984 KL250-C2
1985 KL250-D2
1986 KL250-D3
1987 KL250-D4
1988 KL250-D5
1989 KL250-D6
1990 KL250-D7
1991 KL250-D8
1992 KL250-D9
1993 KL250-D10
1994 KL250-D11
1995 KL250-D12
1996 KL250-D13
1997 KL250-D14
1998 KL250-D15
1999 KL250-D16
2000 KL250-D17
2001 KL250-D18
2002 KL250-D19
2003 KL250-D20
2004 KL250-D21
2005 KL250-D22

Table of Contents
Service Information / Model Coverage

Quick Reference
Torque Specs
VIN and Engine Number

Periodic Maintenance
Periodic Maintenance Chart
Air Filter Servicing
Bolts, Nuts, and Fasteners
Brake Fluid
Brake Inspection
Choke Cable Adjustment
Cooling System Inspection
Clutch Inspection
Compression Check
Drive Chain Adjustment
Engine Idle Speed
Engine Oil
Fuel Line
General Lubrication
Spark Arrestor Cleaning
Spark Plug
Steering Inspection
Suspension Inspection
Throttle Free Play
Valve Adjustment

External Components
Engine Guard
Exhaust System
Headlight Cover
Front Fender
Fuel Tank
Radiator Shrouds
Rear Fender
Side Covers

Cooling System
Coolant Reservoir Tank
Radiators and Fan
Water Pump

Fuel System
Carburetor Removal and Installation
Carburetor Overhaul
Fuel Level Inspection
Petcock and Fuel Strainer

Cylinder Head Cover
Camshafts and Rocker Arms
Cylinder Head
Valve Lapping
Valve Guide Replacement
Piston and Cylinder
Clutch Removal
Clutch Installation
Kick Starter
Oil Pump
Primary Drive Gear
Engine Removal
Engine Installation
Balancer Removal
Balancer Installation
Crankcase Bearings
Transmission Shafts

Final Drive
Engine Sprocket
Rear Sprocket

Steering Bearing Service

Front Suspension
Fork Removal and Installation
Fork Oil Change
Fork Disassembly
Fork Assembly

Rear Suspension
Rear Shock Absorber
Swing Arm

Front Disc
Front Caliper
Front Master Cylinder
Rear Drum Brake
Rear Brake Pedal and Rod

Front Wheel
Rear Wheel
Wheel Inspection
Wheel Bearing Replacement

Electrical Systems
Charging System
Ignition System
Instrument Cluster
Fuse and Diode
Turn Signals
KLR 250 Color Wiring Diagrams

In the past, if you wanted to service a KLR 250 motorcycle yourself, you had to buy the Kawasaki Factory Service Manual for a KLR600. The 250 and 600 share many similarities so Kawasaki refers owners to use the 600 manual as a base manual. Any 250 specific information can be found in the 250 supplement manual. So to look up a procedure you would open your 250 supplement manual first and if you couldn’t find the information you were looking for you would find that section in the KLR600 base manual.

Additional information

Weight 2.3 lbs
Dimensions 11 × 9 × 1 in

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