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2002-2005 Kawasaki KLR250 Maintenance Schedule and Service Intervals

2002-2005 Kawasaki KLR250 Stock Image

This is the maintenance schedule with associated service intervals for 2002-2005 Kawasaki KLR250.

The Kawasaki KLR250 is a dual-sport motorcycle intended for both on-road and off-road riding.

This maintenance schedule applies to the following models:

  • 2002 Kawasaki KLR250
  • 2003 Kawasaki KLR250
  • 2004 Kawasaki KLR250
  • 2005 Kawasaki KLR250

In 1984, Kawasaki KLR250 was introduced to the motorcycling public. It is often described as being a better trail bike (due to lighter weight and reduced bulk). The KLR250 has continued to sell well into the 21st century and was discontinued at the end of the 2005 model run.

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Maintenance Schedule for 2002-2005 Kawasaki KLR250

Below is the maintenance schedule for the 2002-2005 Kawasaki KLR250.

The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.

The maintenance for the 2002-2005 Kawasaki KLR250 is broken into two sections: Emission Related and Non-Emissions.

Periodic Maintenance Chart

OperationEvery500 mi (800) km3000 mi (5000 km)6000 mi (10000 km)9000 mi (15000 km)12000 mi (20000 km)15000 mi (25000 km)18000 mi (30000 km)
Emission Related
Idle speed–check †
Throttle grip play–check †
Spark plug–clean and gap †
Valve clearance–check †
Air cleaner element–clean
Air cleaner element–replace5 cleanings
Fuel system–check
Cylinder head bolts — check †
Evaporative emission control system (c)–check †
Spark arrester–cleanEvery 3000 mi (5000 km)
Battery electrolyte level–check †month
Brake fluid level — check †month
Brake fluid — change2 years
Brake play — check †
Brake light switch — check †
Brake lining wear — check † #
Brake hose connection — check †
Fuel hose connection — check
Steering play–check †
Spoke tightness and rim runout–check †
Drive chain wear–check † #
Nuts, bolts, and fasteners — check †
Tire wear–check †
Engine oil–change #year
Oil filter–replace
General Lubrication–perform
Front fork oil–change
Swing arm pivot — lubricate
Brake camshaft — lubricate2 years
Coolant–change2 years
Radiator hoses, connections–check †year
Steering stem bearing–lubricate2 years
Caliper piston seal and dust seal–replace2 years
Master cylinder cup and dust seal–replace2 years
Brake hose–replace4 years
Fuel hose–replace4 years
Drive chain–lubricate #Every 400 mi (600 km)
Dive chain slack–check † #Every 600 mi (1000 km)


K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
†: Replace. add. adjust, or torque if necessary.
(c): California model only
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping

Tyre size and tyre pressure for the 2002-2005 Kawasaki KLR250

The 2002-2005 Kawasaki KLR250 has the following tyres and tyre sizes standard:

  • Front: 3.00-21 4PR DUNLOP K750A
  • Rear: 4.60-17 4PR DUNLOP K750/K150

The manual for the 2002-2005 Kawasaki KLR250 recommends the following tyre pressures (when cold):

  • Front: 150 kPa/21 psi
  • Rear: (up to 97.5 kg/215 lb load) 150 kPa/21 psi
  • Rear: (over 97.5-150kg [215-330lb] load) 175 kPa/25 psi

General information about the 2002-2005 Kawasaki KLR250

The KLR250 is powered by a four-stroke, single-cylinder liquid-cooled engine with dual overhead cams operating four valves for superior performance. Double engine counterbalancers keep the powerplant running smooth from idle to redline, and an automatic cam chain tensioner helps maintain more precise cam timing without maintenance.

The frame for the KLR250 is made of the same high-tech, high-tensile steel used in Kawasaki’s world-class KX motocross machines. A detachable, lightweight aluminum rear subframe simplifies maintenance by providing access to the airbox, carburetor and rear shock.

The KLR250 features an air adjustable front fork and Kawasaki’s UNI-TRAK® rear suspension, providing more than nine inches of travel at both ends to smooth the ride. The latter features adjustable spring preload and rebound damping. Helping to maintain good traction on pavement or dirt roads, the KLR250’s wheels are shod with universal tires, while a single front disc brake and rear drum brake help to ensure smooth, powerful stops.

Manual for the 2002-2005 Kawasaki KLR250

2002-2005 Kawasaki KLR250 Maintenance Schedule Screenshot From Manual

The above maintenance schedule comes directly from the user’s manual for the 2002-2005 Kawasaki KLR250, which is available here.

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