Kawasaki KLX250 maintenance Schedule

Kawasaki KLX250 Motorcycle Comprehensive Maintenance Schedule

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Comprehensive Maintenance Schedule for the Kawasaki KLX250 Motorcycle

The Kawasaki KLX250 is a dual-sport motorcycle that has been in production since 1979. It is also known as the KLX250R, KLX250S, and KLX250SF in different markets. The KLX250 is designed to be a versatile bike that performs well both on and off-road, with a focus on reliability, simplicity, and fun.

Why Riders Love the Kawasaki KLX250

  1. Versatile Dual-Sport Capabilities: Suitable for both on and off-road riding.
  2. Lightweight and Maneuverable: Easy to handle.
  3. Reliable and Low-Maintenance: Engine known for its durability.
  4. Affordable Price Point: Budget-friendly compared to other dual-sports.
  5. Excellent Fuel Efficiency: Cost-effective to run.
  6. Comfortable Ergonomics: Suitable for a wide range of riders.
  7. Extensive Aftermarket Support: Easy to upgrade and customize.

Technical Specifications

The KLX250 has had two main generations:

First Generation (1979-2007):

  • Engine: 249cc liquid-cooled DOHC 4-stroke single cylinder
  • Power: 24 hp @ 9,000 rpm
  • Torque: 14.8 lb-ft @ 7,500 rpm
  • Transmission: 6-speed
  • Suspension: 43mm inverted cartridge fork, Uni-Trak rear suspension
  • Fuel Capacity: 1.9 gallons
  • Dry Weight: 262 lbs

Second Generation (2008-2020):

  • Engine: 249cc liquid-cooled DOHC 4-stroke single cylinder
  • Power: 24 hp @ 8,500 rpm
  • Torque: 14.8 lb-ft @ 6,500 rpm
  • Transmission: 6-speed
  • Suspension: 43mm inverted cartridge fork, Uni-Trak rear suspension
  • Fuel Capacity: 2.0 gallons
  • Curb Weight: 304 lbs
  • Key Differences: Fuel injection (select markets), stronger wheels, updated styling

Fluid Specifications

  • Engine Oil:
    • Type: API SG, SH, SJ, SL, or SM with JASO MA, MA1, or MA2
    • Viscosity: SAE 10W-40
    • Capacity: 1.3 L (dry fill), 1.1 L (oil filter change), 1.0 L (oil change)
  • Coolant:
    • Type: Permanent type antifreeze
    • Capacity: 1.3 L
  • Brake Fluid:
    • Type: DOT3 or DOT4
  • Fork Oil:
    • Type: SAE 10W
    • Capacity: 531 ml (dry fill), 450 ml (service fill) per fork leg

Parts Requiring Regular Maintenance

Every Ride

  • Check tire pressure and condition.
  • Check brake operation and fluid level.
  • Check engine oil level.
  • Check for any fluid leaks.

Every 600 miles (1,000 km) or 1 month

  • Clean and lubricate chain (use chain cleaner and chain lube).
  • Inspect chain slack and adjust if needed (25-35mm of slack).

Every 3,000 miles (5,000 km) or 6 months

  • Change engine oil and filter (requires oil filter wrench).
  • Check and clean air filter (replace as needed).
  • Check valve clearance and adjust if needed (requires feeler gauges).
  • Check and adjust throttle and clutch cable free play.
  • Lubricate pivot points (side stand, brake pedal, etc.).

Every 6,000 miles (10,000 km) or 12 months

  • Replace air filter.
  • Check and adjust steering head bearings.
  • Check wheel bearings for smooth operation.
  • Check spoke tightness on wheels.
  • Check brake pads and discs for wear (replace as needed).
  • Flush and replace brake fluid.
  • Check and adjust drive chain slack and alignment.

Every 12,000 miles (20,000 km) or 24 months

  • Change spark plug (NGK CR8E or equivalent).
  • Check and replace coolant.
  • Check and replace fork oil.
  • Repack muffler if needed.

Maintenance schedule

IntervalMaintenance Tasks
600 mi / 1,000 km– Clean and lube chain
3,000 mi / 5,000 km– Change oil and filter
– Check/clean air filter
– Check valve clearance
– Lube pivot points
6,000 mi / 10,000 km– Replace air filter
– Check steering head bearings
– Check wheel bearings
– Check spoke tightness
– Check brake pads/discs
– Flush brake fluid
– Adjust chain slack
12,000 mi / 20,000 km– Replace spark plug
– Replace coolant
– Replace fork oil
– Repack muffler

Maintenance Q&A

  1. How often should I change the engine oil on my KLX250?
    • Kawasaki recommends changing the oil and filter every 3,000 miles (5,000 km) or 6 months, whichever comes first. If you ride in dusty or wet conditions frequently, consider changing it more often, around every 1,500-2,000 miles.
  2. Can I adjust the valve clearance myself or do I need to take it to a mechanic?
    • Checking and adjusting valve clearance requires some mechanical skill and special tools like feeler gauges. If you are comfortable working on your own bike, you can do it yourself by following the procedure in the service manual. If not, it’s best to have a qualified mechanic do it for you.
  3. What type of chain lube should I use on my KLX250?
    • Use a high-quality chain lube specifically designed for motorcycle chains. Avoid using WD-40 or other general-purpose lubricants, as they can attract dirt and grime. Apply the lube to the inside of the chain and wipe off any excess.
  4. How do I know when my brake pads need to be replaced?
    • Visually inspect the brake pads for wear. Most pads have wear indicator grooves that will disappear when the pad is worn down. Replace the pads when there is about 1mm of friction material left. Also, if you hear any metal-on-metal grinding noise when braking, replace the pads immediately.
  5. What are some signs that my air filter needs to be cleaned or replaced?
    • A dirty air filter can cause poor engine performance, reduced fuel efficiency, and harder starting. If you notice any of these symptoms, or if the filter looks visibly dirty or clogged, it’s time to clean or replace it. Always replace the filter with a high-quality aftermarket filter or OEM Kawasaki part.
  6. How much does a typical valve clearance adjustment cost at a motorcycle shop?
    • The cost can vary depending on your location and the shop’s labor rates, but expect to pay anywhere from $150 to $300 for a valve clearance check and adjustment. This is why it’s a good idea to learn how to do it yourself if you plan on keeping your KLX250 for a long time.
  7. What’s the best way to store my KLX250 if I won’t be riding it for a few months?
    • First, clean the bike thoroughly and apply a coat of wax to protect the paint. Change the oil and filter, and add fuel stabilizer to the gas tank. Inflate the tires to the recommended pressure. Remove the battery and store it on a trickle charger in a cool, dry place. Cover the bike with a breathable cover and store it in a dry, temperature-controlled area if possible.
  8. How often should I replace the spark plug on my KLX250?
    • Kawasaki recommends replacing the spark plug every 12,000 miles (20,000 km) or 24 months. Always use the recommended spark plug type (NGK CR8E or equivalent) and gap it to the correct specification (0.7-0.8mm).
  9. What should I do if I notice a fluid leak under my KLX250?
    • First, identify the type of fluid that is leaking (oil, coolant, brake fluid, etc.). Check the fluid level in the appropriate reservoir and top it off if needed. Clean the area around the leak and try to locate the source. If the leak persists or seems serious, take your bike to a qualified mechanic for diagnosis and repair.
  10. Can I use aftermarket parts on my KLX250 or should I stick with OEM Kawasaki parts?
    • In most cases, high-quality aftermarket parts are just as good as OEM parts and can often save you money. However, be sure to research the brand and read reviews before buying. Stick with reputable brands that are known for their quality and fitment. For critical components like brakes and engine parts, OEM parts may be the safer choice.

Tips for Prolonging the Life of Your Kawasaki KLX250

  1. Follow the recommended maintenance schedule religiously.
  2. Use high-quality fluids and lubricants (engine oil, coolant, brake fluid, etc.).
  3. Clean and lubricate the chain regularly to prevent premature wear.
  4. Avoid excessive idling and rev the engine gently when cold.
  5. Store the bike properly when not in use for extended periods.
  6. Address any issues or leaks promptly to prevent further damage.
  7. Ride smoothly and avoid aggressive shifting or sudden throttle inputs.

Troubleshooting guide

ProblemPossible CausesSolutions
Engine won’t start– Dead battery
– Fouled spark plug
– Clogged fuel line
– Dirty carburetor		– Charge or replace battery
– Clean or replace spark plug
– Clean fuel line and tank
– Clean carburetor
Engine overheating– Low coolant level
– Stuck thermostat
– Damaged radiator
– Faulty water pump		– Add coolant and check for leaks
– Replace thermostat
– Repair or replace radiator
– Replace water pump
Clutch slipping– Worn clutch plates
– Weak clutch springs
– Improper cable adjustment		– Replace clutch plates
– Replace clutch springs
– Adjust clutch cable
Front end wobble– Loose steering head bearings
– Unbalanced tire
– Bent rim
– Worn swingarm bearings		– Adjust steering head bearings
– Balance or replace tire
– Replace rim
– Replace swingarm bearings
Brakes not working properly– Worn brake pads
– Contaminated brake fluid
– Warped brake disc
– Air in brake lines		– Replace brake pads
– Flush and replace brake fluid
– Replace brake disc
– Bleed brake lines

Recommended Tools for Home Maintenance

  • Socket set (metric)
  • Combination wrenches (metric)
  • Allen wrenches (metric)
  • Torque wrench
  • Oil filter wrench
  • Chain breaker and riveting tool
  • Tire irons and bead breaker
  • Spoke wrench
  • Feeler gauges
  • Multimeter

Reliable Sources

Primary References

  1. Wikipedia – Kawasaki KLX250S: Provides an overview of the Kawasaki KLX250S, including its history and model updates.
  2. Autoevolution – Kawasaki KLX: Detailed information on the Kawasaki KLX models, including specifications and user reviews.
  3. BikesWiki – Kawasaki KLX250: Offers detailed specifications and maintenance information for the Kawasaki KLX250.
  4. Kawasaki Australia – KLX250: Official site with detailed specifications and features of the Kawasaki KLX250.
  5. Bikes and Travels – Kawasaki KLX250 Review: User review discussing the performance and reliability of the Kawasaki KLX250.
  6. CityBike – Kawasaki KLX250 Review: In-depth review of the Kawasaki KLX250, highlighting its features and performance.
  7. YouTube – Kawasaki KLX250 Review: Video review discussing the Kawasaki KLX250’s features and capabilities.

Technical and Maintenance Information

  1. Kawasaki Forums – Gen 1 vs Gen 2 Differences: Forum discussion comparing the first and second generations of the Kawasaki KLX250.
  2. On The Back Wheel – Kawasaki KLX250 Review: Detailed review and buying guide for the Kawasaki KLX250S.
  3. Putoline – Kawasaki KLX250 Product Recommendations: Provides product recommendations for oils and lubricants suitable for the Kawasaki KLX250.
  4. Webike – Kawasaki KLX250: Technical specifications and parts information for the Kawasaki KLX250.
  5. Putoline – Kawasaki KLX250 Product Recommendations: Additional product recommendations for the Kawasaki KLX250.
  6. Kawasaki Online Parts – KLX250 Front Hub: Parts diagram and information for the front hub of the Kawasaki KLX250.
  7. ProductReview – Kawasaki KLX250 Manual: Provides the user manual for the Kawasaki KLX250, detailing maintenance procedures and schedules.

Additional References

  1. ADVrider – KLX250 Flaws: Forum discussion about the common flaws and issues with the Kawasaki KLX250.
  2. Kawasaki Forums – KLX250 Maintenance: Forum discussion providing tips and advice on maintaining the Kawasaki KLX250.
  3. Thumper Talk – KLX250S Oil Changes: Forum discussion about the frequency of oil changes for the Kawasaki KLX250S.
  4. Supermoto Junkie – KLX250SF Service Intervals: Forum discussion about the recommended service intervals for the Kawasaki KLX250SF.