Do you need to service your Kawasaki KLR250 dual sport motorcycle? The Kawasaki KLR250 Service Manual by Cyclepedia Press LLC includes 413 pages of service, repair and maintenance information. With every purchase of the printed book you also get access to the full-color online version and technical support for one year.
Table of Contents
Service Information / Model Coverage
VIN and Engine Number
Periodic Maintenance Chart
Air Filter Servicing
Bolts, Nuts, and Fasteners
Choke Cable Adjustment
Cooling System Inspection
Drive Chain Adjustment
Engine Idle Speed
Spark Arrestor Cleaning
Throttle Free Play
Coolant Reservoir Tank
Radiators and Fan
Carburetor Removal and Installation
Fuel Level Inspection
Petcock and Fuel Strainer
Cylinder Head Cover
Camshafts and Rocker Arms
Valve Guide Replacement
Piston and Cylinder
Primary Drive Gear
Steering Bearing Service
Fork Removal and Installation
Fork Oil Change
Rear Shock Absorber
Front Master Cylinder
Rear Drum Brake
Rear Brake Pedal and Rod
Wheel Bearing Replacement
Fuse and Diode
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.
The Kawasaki KLR250 is a versatile and reliable dual-sport motorcycle known for its durability and capability both on-road and off-road. While it’s generally considered a reliable bike, some owners have reported certain issues or areas that might need attention.
Oil Consumption: Some riders have reported higher oil consumption. Regularly check the oil levels and perform oil changes at recommended intervals.
Carburetor Tuning: Carburetor-related issues, such as tuning problems or clogged jets, have been reported. Regularly clean and maintain the carburetor for optimal performance.
Electrical System: Over time, electrical components like the battery and wiring may require attention. Check the battery, electrical connections, and lighting systems.
Rust on Exhaust System: The exhaust system may be prone to rust, especially in humid or wet conditions. Regularly inspect and address any rust-related issues.
Suspension Maintenance: The front forks and rear shock should be inspected for leaks and wear. Maintain proper suspension function for on-road and off-road performance.
Chain and Sprockets: Regularly inspect and adjust the chain tension. Replace the chain and sprockets if signs of wear are present.
Brake System: Check the brake pads, brake fluid levels, and ensure the braking system’s reliability. Off-road riding can be demanding on brakes.
Tire Wear: Dual-sport bikes are often used on a variety of terrains, which can accelerate tire wear. Regularly check and replace tires as needed.
Frame and Chassis Integrity: Inspect the frame and chassis for any signs of cracks or damage. Off-road riding can put stress on the bike’s structure.
Fuel System Cleaning: Perform periodic fuel system cleaning to ensure optimal fuel delivery and combustion.
Regular maintenance, along with proactive checks and adjustments, can contribute to a trouble-free riding experience.