Definitive Kawasaki KLX250S Motorcycle Owner's Manual – Maintenance & Troubleshooting Guide 2014

Kawasaki KLX250S Owner's Manual - 2014 Edition

This technical document serves as the authoritative operational framework for the KLX250S series, detailing necessary procedures for maintaining factory-standard performance. It integrates a critical high-altitude performance protocol, specifying that vehicles operated above 4,000 feet require specific carburetor modifications to ensure emission compliance and engine efficiency. Utilizing the standard NGK CR8E spark plug with a precisely calibrated gap of 0.7 to 0.8 mm is essential for optimal thermal combustion and preventing electrical system fatigue.

Technical Applicability & Chassis Configurations

The documentation is structured to support the 249 cm³ DOHC single-cylinder platform across specific regional and weight-based variants:

• Standard KLX250S (KLX250SEF)
  • Curb Mass: 135 kg (298 lb)
  • Engine Architecture: Liquid-cooled, 4-stroke
• California Emission Variant (KLX250SEF - CAL)
  • Curb Mass: 136 kg (300 lb)
  • System Features: Integrated Evaporative Emission Control System with specialized vacuum hose routing

Operational Reliability & System Protection

• Engine Integrity Management: Adherence to the 1,600 km (1,000 mi) break-in schedule, with speed restricted to 4,000 rpm for the first 800 km, is mandatory to ensure proper component seating.
• Drivetrain Precision: Maintaining drive chain slack between 35 and 45 mm prevents excessive stress on the sprockets and countershaft bearings.
• Safety Benchmark Compliance: Daily verification of brake pad lining

System Depth & Factory Benchmarks

Engine performance is regulated by precise electronic and mechanical specifications to maintain factory-calibrated output:

• Ignition Synchronization: 10° BTDC @ 1,300 r/min scaling to 25° BTDC @ 5,000 r/min.
• Compression Ratio: 11.0: 1.
• Thermodynamic Management: Idle speed must be maintained between 1,250 and 1,350 r/min (rpm) to ensure stable oil pressure and cooling.

Visual Navigation Aids & Interface Layout

The manual provides comprehensive mapping of the digital instrumentation and mechanical control points:

• Multi-Function Meter: Features a digital speedometer, tachometer with a designated "red zone" above 10,500 rpm, and a dual-trip odometer.
• Fluid Inspection: A dedicated sight glass on the lower right engine casing allows for immediate wet sump lubricant verification.
• Electrical Protection: The 20A main fuse is strategically located on the starter relay beneath the seat assembly.

Table of Contents

• Specifications: Detailed performance and dimensional data.
• General Information: Instrumentation, switchgear, and fuel requirements.
• How to Ride: Engine startup, shifting patterns, and braking techniques.
• Maintenance and Adjustment: Periodic maintenance charts and component-specific service steps.
• Troubleshooting: Logic-based diagnostic guides for engine and electrical issues.

Operational Limits & Fluid Specifications

• Engine Lubricant: SAE 10W-40 (API SG to SM; JASO MA/MA1/MA2).
• Oil Capacity: 1.0 L (standard change), 1.1 L (with filter), 1.3 L (dry engine).
• Cooling System: 1.3 L capacity using a 50/50 ethylene glycol and soft water mixture.
• Component Torques: Oil drain plug at 15 N-m; Rear axle nut at 110 N-m.