Kawasaki KLX250 S 2013, KLX 250 S 2014 Owner's manual

Quick Reference Guide

This Quick Reference Guide will
assist you in finding the information
you’re looking for.

A Table of Contents is included after
the Foreword.

GENERAL INFORMATION j

HOW TO RIDE THE MOTORCYCLE j

SAFE OPERATION j

MAINTENANCE AND ADJUSTMENT j

STORAGE j

TROUBLESHOOTING GUIDE j

Whenever you see the symbols
shown below, heed their instructions!
Always follow safe operating a nd main­tenance practices.

DANGER

DANGER indicates a hazardous

situation which, if not avoided,

will result in death or serious in-

jury.

WARNING

WARNING indicates a hazardous

situation which, if not avoided,

could result in death or serious

injury.

NOTICE

NOTICE is used to address prac­ticesnotrelatedtopersonalin­jury.

NOTE

NOTE indicates information that may

○

help or guide you in the operation or
service of the vehicle.

WARNING

Engine exhaust, some of its
constituents, and certain vehi­cle components contain or emit
chemicals known to the State of
California to cause cancer and
birth defects or other reproduc­tive harm.

NOTICE

THIS PRODUCT HAS BEEN
MANUFACTURED FOR USE IN A
REASONABLE AND PRUDENT
MANNER BY A QUALIFIED OP­ERATOR AND AS A VEHICLE
ONLY.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo­torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety a nd performance.

Please read this Owner’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle’s controls, its fea­tures, cap ab ilitie s, and limitations. This manual offers many safe rid ing tips, but its
purpose is not to provide instruction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi­cle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in­formation on their Kawasaki Mot orcycle, a Service Manual is a va ilable for purchase
from any authorized Kawasaki motorcycle dealer. The Service Manual contains de­tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the Service Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.

This manual should be considered a permanent part of the motorcycle and should

remain with the motorcycle when it is sold.

All rights reserved. No part of this publication may be reproduced without our

prior written permission.

This p ublication includes the la te st information available at the time of pr inting .
However, there may be minor differences between the actual product and illustra­tions and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

© 2013 Kawasaki Heavy Industries, Ltd. Mar. 15, 2013. (1)

TABLE OF CONTENTS

SPECIFICATIONS............................... 9

SERIAL NUMBER L OCATIONS......... 13

LOCATION OF PARTS....................... 14

LOCATION OF LABELS..................... 17

LOADING INFORMATION.................. 21

GENERAL INFORMATION................. 24

Meter Instruments ............................ 24

Meter Instruments: ........................ 25

Tachometer:.................................. 25

Speedometer : .............................. 25

Odometer/Trip Meter AB:.............. 26

Warning/Indicator Light:................ 30

Keys ................................................. 31

Ignition Switch/Steering Lock ........... 32

Right Handlebar Switches ................ 34

Engine Stop Switch: ..................... 34

Starter Button: .............................. 34

Left Handlebar Switches .................. 35

Dimmer Switch: ............................ 35

Turn Signal Switch: ....................... 35

Horn Button: ................................. 35

Fuel Tank Cap .................................. 36

Fuel Tank ......................................... 37

Fuel Requirement: ........................ 38

Fuel Tap ........................................... 41

Stand................................................ 42

Helmet Hook .................................... 43

Tool Kit Bag/Tool Kit ......................... 44

Seat.................................................. 45

Rear View Mirror .............................. 46

BREAK-IN ........................................... 47

HOW TO RIDE THE MOTORCYCLE .49

Starting the Engine .......................... 49

Jump Starting ................................... 52

Moving Off........................................ 55

Shifting Gears .................................. 56

Braking............................................. 58

Stopping the Engine......................... 59

Stopping the Motorcycle in an

Emergency ................................... 60

Parking............................................. 61

Catalytic Converter........................... 63

SAFE OPERATION............................. 65

Safe Riding Technique ..................... 65

Daily Checks .................................... 68

Additional Considerations for Off

Road Operation ............................ 71

Additional Considerations for High

Speed Operation .......................... 72

MAINTENANCE AND ADJUSTMENT 74

Periodic Maintenance Chart............. 79

Engine Oil ........................................ 91

Cooling System ................................ 97

Spark Plugs...................................... 102

Kawasaki Clean Air System ............. 103

Evaporative Emission Control

System (California model only)..... 104

Valve Clearance ............................... 105

Air Cleaner ....................................... 106

Throttle Grip ..................................... 111

Carburetors ...................................... 114

Clutch............................................... 116

Drive Chain ...................................... 119

Brakes.............................................. 125

Brake Light Switches........................ 129

Front Fork......................................... 131

Rear Shock Absorber....................... 133

Wheels ............................................. 136

Battery.............................................. 140

Headlight Beam................................ 146

Fuses ............................................... 148

General Lubrication.......................... 150

Cleaning Your Motorcycle ................ 151

Bolt and Nut Tightening.................... 157

STORAGE........................................... 159

TROUBLESHOOTING GUIDE............ 162

YOUR WARRANTY/OWNER

SATISFACTION .............................. 163

REPORTING SAFETY DEFECTS ...... 169

ENVIRONMENTAL PROTECTION..... 170

MAINTENANCE RECORD ................. 171

LABEL INFORMATION ...................... 176

SPECIFICATIONS

PERFORMANCE

Minimum Turning Radius

DIMENSIONS

Overall Length 2 200 mm (86.62 in.)

Overall Width 820 mm (32.28 in.)

Overall Height 1 205 mm (47.44 in.)

Wheelbase

Road Clearance 285 mm (11.22 in.)

CurbMass 135kg(298lb)

ENGINE

Type

Displacement

Bore x Stroke 72.0 × 61.2 mm (2.83 × 2.41 in.)

Compression Ratio

2.4m(94.5in.)

1 430 mm (56.30 in.)

(CAL) 136 kg (300 lb)

DOHC, single-cylinder, 4-stroke, liquid-cooled

249cm³(15.2cuin.)

11. 0 : 1

SPECIFICATIONS 9

10 SPECIFICATIONS

Starting System

Carburetors KEIHIN CVK34

Ignition System CDI

Ignition Timing
(Electronically advanced)

Spark Plugs NGK CR8E

Lubrication System Forced lubrication (wet sump)

Engine Oil

Type:

Viscosity:

Capacity:

Coolant Capacity 1.3 L (1.4 US qt)

TRANSMISSION

Transmission Type

Clutch Type

Driving S ystem Chain drive

Primary Reduction Ratio

Electric starter

10° BTDC @1 300 r/min (rpm) ∼ 25° BTDC @5 000

r/min (rpm)

API SG, SH, SJ, SL or SM with JASO MA, MA1 o r MA2

SAE 10W-40

1.3L(1.4USqt)

6-speed, constant mesh, return shift

Wet, multi disc

2.800 (84/30)

SPECIFICATIONS 11

Final Reduction Ratio

3.000 (42/14)

Overall Drive Ratio 8.000 (Top gear)

Gear Ratio

1st 3.000 (30/10)

2nd

3rd

4th

5th

6th

2.000 (30/15)

1.500 (27/18)

1.250 (25/20)

1.050 (21/20)

0.952 (20/21)

FRAME

Castor 26.5°

Trail 105 mm (3.31 in.)

Tire Size:

Front 3.00-21 51P

Rear

4.60-18 63P

12 SPECIFICATIONS

Rim Size:

Front 21 × 1.60

Rear

Fuel Tank Capacity 7.7 L (2.04 US gal)

ELECTRICAL EQUIPMENT

Battery 12V6Ah

Headlight 12 V 60/55 W

Tail/Brake Light 12 V 5/21 W

18 × 2.15

(CAL) California model
Specifications are subject to change without notice.

SERIAL NUMBER LOCATIONS 13

SERIAL NUMBER LOCATIONS

The engine and frame serial numbers are used to register the motorcycle. They
are the only means of identifying your particular machine from others of the same
model type. These serial numbers may be needed by your dealer when ordering
parts. In the event of theft, the investigating authorities will require both numbers
as well as the model type and any peculiar features of your machine that can help
them id entify it.

Frame No.

A. Frame Number

Engine N o.

A. Engine Number

14 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever

2. Meter Instruments

3. Brake Fluid Reservoir (Front)

4. Front Brake Lever

5. Left Handlebar Switches

6. Ig nit ion Switch/Steering Lock

7. R ight Handlebar Switches

8. T hro ttle Grip

LOCATION OF PARTS 15

9. Front Fork

10. Headlight

11. Turn Signal Light

12. Fuel Tank Cap

13. Fuel Tank

14. Choke Knob

15. Fuel Tap

16. R ear Sho ck Absorber

17. Tool Kit Bag

18. Tool Kit

19. Helmet Hook

20. B rake Disc

21. B rake Caliper

22. R adiator

23. Horn

24. Shift Pedal

25. Side Stand

26. Side Stand Switch

27. Drive Chain

28. Coolant Reserve Tank

29. Battery

16 LOCATION OF PARTS

30. License Plate Light

31. Tail/Brake Light

32. Muffler

33. S eat

34. Air Cleaner Element

35. Carb uretor

36. Idle Adjusting Screw

37. Front Brake Light
Switch

38. Radiator Cap

39. Brake Fluid Reservoir
(Rear)

40. R ear Brake Light
Switch

41. Oil Level Inspection
Window

42. R ear Brake Pedal

43. Speedo me ter Lead

LOCATION OF LABELS

LOCATION OF LABELS 17

All warning labels which are on your
vehicle are repeated here. Read labels
on your vehicle and understand them
thoroughly. They contain information
which is important for your safety and
the safety of anyone else who may op­erate you r vehicle. Therefore, it is very
important that all warning labels be on
your vehicle in the locations shown. I f
any label is missing, damaged, or worn,
get a replacement from your Kawasaki
dealer and install it in the correct posi­tion.

NOTE

The sample warning labels in this

○

section have part numbers to help

you and your dealer obtain the cor­rect replacement.
Refer to the actual vehicle label for

○

model specific data grayed out in th e
illustration.

1. Brak e Fluid (Front)

18 LOCATION OF LABELS

2. Im po rtan t Drive Chain Information

3. Tire and Load Data

4. B ra ke Fluid (Re ar)

(For further information of label,
refer to the “LABEL INFORMATION”
chapter.)

LOCATION OF LABELS 19

5. Weight and Manufacture

6. Vehicle Emission Control Information

*7. Vacuum Hose Routing Diagram

8. Noise Emission Control Information

(For further information of label,
refer to the “LABEL INFORMATION”
chapter.)

*: Only on California model

20 LOCATION OF LABELS

*9. Fuel Level

10. B attery Poison/Danger

11. Radiator Cap Danger

(For further information of label,
refer to the “LABEL INFORMATION”
chapter.)

*: Only on California model

LOADING INFORMATION

LOADING INFORMATION 21

WARNING

Incorrect loading, improper in-

stallation or use of accessories,

or modification of your motorcy-

cle may result in an unsafe riding

condition. Before you ride the

motorcycle, make sure it is not

overloaded and that you have

followed these instructions.

With the exception of genuine
Kawasaki Parts and Accessories,
Kawasaki has no control over the
design or application of accessories.
In some cases, improper installation
or use of accessories, or motorcycle
modification, will void the motorcycle
warranty. In selecting and using acces­sories, and in loading the motorcycle,

you are personally responsible for your
own safety and the safety of other per­sons involved .

NOTE

Kawasaki Parts and Accessories

○

have been specially designed for
use on Kawasaki motorcycles. We
strongly recommend that all parts
and accessories you add to your
motorcycle be genuine Kawasaki
components.

Because a motorcycle is s en sitive to
changes in weight and aerodynamic
forces, you must take extreme care
in carrying cargo, passengers and/or
in the fitting of additional accessories.
The following general guidelines have

22 LOADING INFORMATION

been prepared to assist you in making
your determinations.

1. Any passenger should be thor­oughly familiar with motorcycle op­eration. The passenger can affect
control of the motorcycle by im­proper positioning during cornering
and sudden movements. It is impor­tant that the passenger sit still while
the motorcycle is in motion and not
interfere with the operation of the
motorcycle. Do not carry animals
on your motorcycle.

2. You should instruct any passenger
before riding to keep his feet on the
passenger footpegs and hold on to
the operator or seat strap. Do not
carry a passenger unless he or she
is tall enough to reach the footpegs
and footpegs are provided.

3. All baggage should be carried as
low as possible to reduce the effect

on the motorcycle center of gravity.
Baggage weight should also be dis­tributed equally on both sides of the
motorcycle. Avoid carrying baggage
that extends beyond the rear of the
motorcycle.

4. Baggage should be securely at­tached. Make sure that the baggage
will not move around while you are
riding. Recheck baggage security
as often as possible (not while the
motorcycle is in motion) and adjust
as necessary.

5. Do not carry heavy or bulky items on
a luggage rack. They are designed
for light items, and overloading can
affect handling due to changes in
weight distribution and aerodynamic
forces.

6. Do not install accessories or carry
baggage that impairs the perfor­mance of the motorcycle. Make
sure that you have not adversely

LOADING INFORMATION 23

affected any lighting components,
road clearance, banking capability
(i.e., lean angle), control operation,
wheel travel, front fork movement,
or any other aspect of the motorcy­cle’s operation.

7. Weight attached to the handlebar or
front fork will increase the mass of
the steering assembly and can r e­sult in an unsafe riding condition.

8. Fairings, windshields, backrests,
and other large items have the ca­pability of adversely affecting stabil­ity and handling of the motorcycle,
not only because of their weight, but
also due to the aerodynamic forces
acting on these surfaces while the
motorcycle is in operation. Poorly
designed or installed items can re­sult in an unsafe riding condition.

9. This motorcycle was not intended
to be equipped with a sidecar or to

be used to tow any trailer or other
vehicle. Kawasaki does not manu­facture sidecars or trailers for mo­torcycles and cannot predict the ef­fects of such accessories on han­dling or stability, but can only warn
thattheeffectscanbeadverseand
that Kawasaki cannot assume re­sponsibility for the results of s uch
unintended use of the motorcycle.
Furthermore, any adverse effects on
motorcycle components caused by
the use of such accessories will not
be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage,
and accessories must not exceed 181 kg
(399 lb).

24 GENERAL INFORMATION

Meter Instruments

A. MODE Button
B. RESET Button
C. Tachometer
D. Odometer/Trip Meter AB
E. Speedometer
F. C l o c k
G. Coolant Temperature

Warning Indicator Light
H. High Beam Indicator Light
I. Neutral Indicator Light
J. Turn Signal Indicator Light
K. Red Zone

GENERAL INFORMATION

GENERAL INFORMATION 25

Meter Instruments:

The meter displays all segments for
a few seconds when the ignition key is
turned to “ON”. The tachometer mo­mentarily goes from the minimum to
the maximum, then goes back from the
maximum to the minimum reading to
check its operation. If any meter instru­ments or tachometer does not operate
or display correctly, have it checked by
an authorized Kawasaki dealer.

Tachometer:

The tachometer shows the engine
speed in revolutions per m in ute (r/min,
rpm). On the right side of the tachome­ter face is a portion called the “red
zone”. Engine r/ min (rpm) in the
red zone is above maximum recom­mended engine speed and is also
above the range for good performance.

NOTE

This motorcycle is equipped with the

○

engine speed limitter to prevent the
excesive high engine speed. When
operating this limitter, the segments
of the tac hometer indicate the differ­ent engine speed and stops at about
5000 r/min (rpm) for the ignition con­trol, but this operation is not a failure.

NOTICE

Engine r/min (rpm) should not
be allowed to enter the red zone;
operation in the red zone will
overstress the engine and may
cause serious engine damage.

Speedometer :

The speedometer shows the speed

of the vehicle in digital values.

26 GENERAL INFORMATION

Odometer/Trip Meter AB:

This meter displays the odometer,
thetripmeterAB,andthefuelwarning
message.

The odometer and the trip meter AB
canbeshiftedpushingtheMODEbut­ton.

A. Odometer
B. Trip meter A
C. Trip meter B
D. MODE Button

NOTE

Do not shift the odometer/trip meter

○

while riding for safe operation.

Odometer -

The odometer shows the total dis­tance in kilometers or miles that the ve­hicle has been ridden. This meter can­not be reset.

NOTE

The data is maintained even if the

○

battery is disconnected.
When the figures come to 999999,

○

they are stopped and locked.

Trip Meters A/B -

The trip meter shows the distance in
kilometers or miles traveled since it was
last reset to zero.

To r e s e t th e t r i p me t e r :

GENERAL INFORMATION 27

PushtheMODEbuttontodisplaythe

•

trip meter A or B.
Push the RESET button and hold it

•

in.
After two second, the figure display

•

turns to 0.0, and then starts counting
when the vehicle is operated. The
meter counts until it is next reset.

NOTE

The data is maintained by the back

○

-up power if the ignition key is turned
off.
When the trip meter reaches 999.9

○

(TRIPA)or9999.9(TRIPB)while
riding, the meter resets to 0.0 and
continues counting.
When the battery is disconnected,

○

the m eter display resets to 0.0.

Mile/Km Display:

Mile/Km Display can alternate be­tween English and metric modes (mph
and km/h) in the meter unit. Make sure
that km/h or mph according to local
regulations is correctly displayed be­fore riding.

28 GENERAL INFORMATION

NOTE

Do not operate the vehicle with

○

the m eter unit displaying in the
wrong unit (km/h or mph). Shift
the km/h·mph display in the meter
unit as follows.

Display the odometer.

•

The km/h·mph display shifts by push-

•

ing the RESET button while the
MODE button pushed in.

A. Km/h·Mph Display

The km/h/mph display shifts as fol-

•

lows.

A. Km/h
B. Mph
C.PushRESETButtonwithMODEButtonin

NOTE

The data is maintained even if the

○

battery is disconnected.

Clock:

To adjust hours and minutes:

Turn the ignition key to “ON”.

•

Push the RESET button for more

•

than two seconds. Both the hour and
minute displays start blinking.

GENERAL INFORMATION 29

Push the RESET button. The hour

•

display only blin ks. Push the MODE
button to advance the hours.

Push the RESET button. The hour

•

display stops blinking and the minute
display starts blinking. Push the
MODEbuttontoadvancethemin­utes.

Push the RESET b u tton. Both the

•

hour and minute displays start blink­ing again.
Push the MODE button. The dis-

•

plays stop blinking and the clock
starts working.

NOTE

Pushing the MODE button momen-

○

tarily advances the hour or minute
step by step. Pushing and hold­ing the button advances the hour or
minute continuously.
The clock works normally from the

○

back-up power while the ignition
switch is turned off.