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Kawasaki KLR250 Maintenance Schedule and Service Intervals

2002-2005 Kawasaki KLR250 Stock Image

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

The Kawasaki KLR250 is a dual-sport motorcycle, equally adept at on- and off-road riding. Kawasaki introduced the KLR250 in 1984, building it for over two decades until it was discontinued in 2005.

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Maintenance Schedule for Kawasaki KLR250

Below is the maintenance schedule for the 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 Kawasaki KLR250 is broken into two sections: Emission Related and Non-Emissions.

Notes on the maintenance schedule:

  • For higher odometer readings, repeat at the frequency interval established here
  • K: Should be serviced by an authorized Kawasaki dealer (per Kawasaki)
  • †: Replace. add. adjust, or torque if necessary.
  • # (air filter, chain, etc.): Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
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, replace if necessary (NGK DP9EA-9)
Valve clearance–check †
Air cleaner element–clean
Air cleaner element–replace5 cleanings
Fuel system–check
Cylinder head bolts — check †
Evaporative emission control system — check (CA only)
Non-Emissions
Spark arrester–cleanEvery 3000 mi (5000 km)
Battery electrolyte level–check †month
Brake fluid level — check †month
Brake fluid — change (DOT 4 only)2 years
Brake play — check †
Brake light switch — check †
Brake lining wear — check † #
Brake hose connection — check †
Fuel hose connection — check
Clutch — adjust
Steering play–check †
Spoke tightness and rim runout–check †
Drive chain wear–check † #
Nuts, bolts, and fasteners — check †
Tire wear–check †
Engine oil — change (Kawasaki 10W-40 engine oil)year
Oil filter — replace (HF123)
General Lubrication–perform
Front fork oil–change
Swing arm pivot — lubricate
Brake camshaft — lubricate2 years
Coolant — change (ethylene glycol pre-mix)2 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 # (Motul chain paste)Every 400 mi (600 km)
Drive chain slack–check † #Every 600 mi (1000 km)
Kawasaki KLR250 maintenance schedule table

Tyre size and tyre pressure for the Kawasaki KLR250

The 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 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 Kawasaki KLR250

The KLR250 is powered by a 249cc four-stroke, single-cylinder carburettor-fed liquid-cooled engine with dual overhead cams operating four valves per cylinder… its single cylinder, that is.

The engine produces a stomping 22.3 kW (30 hp) at the crank, and less than that at the rear wheel, at 8,500 rpm. And torque is 19 ft-lb (26 Nm) @ 7,500 rpm, but it comes on sooner — this isn’t an engine you have to rev up to have fun.

Power goes to the ground via a six speed transmission and chain drive. In theory you can ride the KLR250 above 100 km/h, and it’ll get there, but you will likely have the throttle near its limit.

Double engine counterbalancers keep the powerplant running smooth from idle to redline, and an automatic cam chain tensioner helps maintain more precise cam timing with minimal maintenance.

Kawasaki made the KLR250’s frame from the same high-tensile steel used in Kawasaki’s world-class KX motocross machines. So even though this is a dual-sport motorcycle not intended to land massive jumps, the chassis is up to it.

The KLR250 has an air adjustable front fork and Kawasaki’s trademark UNI-TRAK® rear suspension, with a whopping nine inches of travel at both ends to smooth the ride over rough surfaces. The rear suspension has both adjustable 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 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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