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Kawasaki · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

KLR 250

Library entry covers 1984-2008

39 factory 34 guideline

Published source

Kawasaki 2005 KLR250 KL250-D22 Owner's Manual 99987-1265 (US, English), Periodic Maintenance Chart pp.56-58

Factory owner's handbook. Covers KL250-D22 KLR250; 2005 US owner's manual 99987-1265, English. Chart columns in mi (km): 500/3000/6000/9000/12000/15000/18000 mi (800/5000/10000/15000/20000/25000/30000 km) plus 'Every' column, whichever comes first; for higher odometer readings repeat at the frequency interval established. K = should be serviced by an authorized Kawasaki dealer; dagger = replace, add, adjust, or torque if necessary; # = service more frequently in severe conditions; (c) = California model only. Liquid cooled, chain final drive.

Open the source

73 items for a 2002 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2002 Kawasaki KLR 250

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 600 km

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain - lubricate. Factory: Every 400 mi (600 km), printed as text; #: service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping (p.58)

Every 1,000 km

1 item

Drive chain slack - check

Final drive

Factory

Factory: Every 600 mi (1000 km), printed as text; dagger: replace, add, adjust, or torque if necessary; #: service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping (p.58)

Every 1,600 km or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 5,000 km or 1 month

2 items

Battery electrolyte level - check

Ignition and electrics

Factory

Factory: Every: month; Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary (p.56)
Brake fluid level - check

Brakes

Factory

Factory: Every: month; Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary (p.56)

Every 5,000 km or 12 months

6 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 5,000 km

17 items

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance - check. Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary; emission related (p.56)
General lubrication - perform

Engine

Factory

Factory: Marked 3000-18000 mi (5000-30000 km); not at 500 mi initial (p.57)
Idle speed - check

Engine

Factory

Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary; emission related (p.56)
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug - clean and gap. Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary; no replacement interval printed; emission related (p.56)
Spark arrester - clean

Engine

Factory

Factory: Every 3000 mi (5000 km), printed as text (p.56)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle grip play - check. Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary; emission related (p.56)
Fuel hose connection - check

Fuel and air

Factory

Factory: Marked 3000-18000 mi (5000-30000 km); not at 500 mi initial; no dagger; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.57)
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch - adjust. Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km) (p.57)
Drive chain wear - check

Final drive

Factory

Factory: Marked 3000-18000 mi (5000-30000 km); not at 500 mi initial; dagger: replace, add, adjust, or torque if necessary; #: service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping (p.57)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering play - check. Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.57)
Brake hose connection - check

Brakes

Factory

Factory: Marked 3000-18000 mi (5000-30000 km); not at 500 mi initial; dagger: replace, add, adjust, or torque if necessary; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.57)
Brake light switch - check

Brakes

Factory

Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary (p.56)
Brake play - check

Brakes

Factory

Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary (p.56)
Check brake pads and discs

Brakes

Factory

Manual: Brake lining wear - check. Factory: Marked 3000-18000 mi (5000-30000 km); not at 500 mi initial; dagger: replace, add, adjust, or torque if necessary; #: service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping (p.57)
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tire wear - check. Factory: Marked 3000-18000 mi (5000-30000 km); not at 500 mi initial; dagger: replace, add, adjust, or torque if necessary (p.57)
Spoke tightness and rim runout - check

Wheels and tires

Factory

Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.57)
Evaporative emission control system - check (California model only)

Controls and cables

Factory

Factory: Every column incl. 500 mi (800 km) initial, then every 3000 mi (5000 km); dagger: replace, add, adjust, or torque if necessary; (c) California model only (p.56)

Every 6,500 km or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 9,500 km or 12 months

6 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km or 12 months

2 items

Change engine oil

Engine

Factory

Manual: Engine oil - change. Factory: Every: year; Marked at 500, 6000, 12000, 18000 mi (800, 10000, 20000, 30000 km); #: service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping (p.57)
Inspect coolant hoses and clamps

Engine

Factory

Manual: Radiator hoses, connections - check. Factory: Every: year; Marked at 500, 6000, 12000, 18000 mi (800, 10000, 20000, 30000 km); dagger: replace, add, adjust, or torque if necessary (p.58)

Every 10,000 km

7 items

Cylinder head bolts - check

Engine

Factory

Factory: Marked at 500, 6000, 12000, 18000 mi (800, 10000, 20000, 30000 km); dagger: replace, add, adjust, or torque if necessary; emission related (p.56)
Nuts, bolts, fasteners - check

Engine

Factory

Factory: Marked at 500, 6000, 12000, 18000 mi (800, 10000, 20000, 30000 km); dagger: replace, add, adjust, or torque if necessary (p.57)
Replace oil filter

Engine

Factory

Manual: Oil filter - replace. Factory: Marked at 500, 6000, 12000, 18000 mi (800, 10000, 20000, 30000 km); no Every entry (p.57)
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner element - clean. Factory: Marked at 3000, 9000, 15000 mi (5000, 15000, 25000 km); spacing 6000 mi (10000 km); emission related (p.56)
Fuel system - check

Fuel and air

Factory

Factory: Marked at 6000, 12000, 18000 mi (10000, 20000, 30000 km); not at 500 mi; no dagger; emission related (p.56)
Replace air filter element

Fuel and air

Factory

Manual: Air cleaner element - replace. Factory: Every column printed as '5 cleanings'; marked at 6000, 12000, 18000 mi (10000, 20000, 30000 km); emission related (p.56)
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swing arm pivot - lubricate. Factory: Marked at 6000, 12000, 18000 mi (10000, 20000, 30000 km); not at 500 mi; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.57)

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,500 km or 2 years

1 item

Clean and grease rear suspension linkage

Rear suspension and frame

Guideline

Every 20,000 km or 2 years

3 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering stem bearing - lubricate. Factory: Every: 2 years; single mark at 12000 mi (20000 km); dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.58)
Brake camshaft - lubricate

Brakes

Factory

Factory: Every: 2 years; single mark at 12000 mi (20000 km); dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.57)
Replace brake fluid

Brakes

Factory

Manual: Brake fluid - change. Factory: Every: 2 years; single mark at 12000 mi (20000 km); not a K item (p.56)

Every 24,000 km or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 25,500 km or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 30,000 km or 2 years

1 item

Replace coolant

Engine

Factory

Manual: Coolant - change. Factory: Every: 2 years; single mark at 18000 mi (30000 km); not a K item (p.57)

Every 30,000 km

1 item

Change fork oil

Front end

Factory

Manual: Front fork oil - change. Factory: Single mark at 18000 mi (30000 km); dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.57)

Every 32,000 km or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

4 items

Caliper piston seal and dust seal - replace

Engine

Factory

Factory: Every: 2 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.58)
Master cylinder cup and dust seal - replace

Engine

Factory

Factory: Every: 2 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.58)
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose - replace. Factory: Every: 4 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.58)
Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake hose - replace. Factory: Every: 4 years; no odometer marks; dealer item (K: should be serviced by an authorized Kawasaki dealer) (p.58)
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.