Kawasaki KLR250 Maintenance Schedule and Service Intervals

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, a little sibling to the indomitable Kawasaki KLR650. Kawasaki introduced the KLR250 in 1984, building it for over two decades until it was discontinued in 2005, and replaced by the Kawasaki KLX250S from 2006.

Updated December 2023 — incorrectly had referred to the engine as air-cooled in one segment.

Kawasaki KLR250 red RHS
Kawasaki KLR250

This site has links for things like oil and spark plugs from which we earn a commission (which unfortunately nobody can save, not even us). If you appreciate this work, then please use those links. Thanks!

Kawasaki KLR250 Service Intervals

The KLR250 has 3000 mile / 5000 km service intervals. While you only have to change the oil every 6000 miles / 10000 km, some owners change the oil at this interval too, particularly if riding off-road. However, it’s not required.

At every 3000 mile / 5000 km service, also check the spark plug and the valve clearances. The KLR250 has a 4-valve head so there are four clearances to check. However, the valves are a screw-and-locknut type, so can be done by the backyard mechanic with relative ease (though tightening the valve and keeping the clearance is fiddly, as always.

Since the KLR has a liquid-cooled engine, make sure you regularly change the coolant. Also, keep the brake fluid fresh, replacing it every couple of years.

Kawasaki KLR250 valve clearance adjustment
Kawasaki KLR250 valve clearance adjustment Source: Mech It Better, YouTube

Maintenance Schedule for Kawasaki KLR250

Below is the maintenance schedule for the Kawasaki KLR250. It’s split into a regular annual service checklist, plus the list of intermittent maintenance items.

For higher odometer readings, repeat at the frequency interval established below, doing actions every 1, 2, 3, or 4 service intervals.

mi x 1000369121518
km x 100051015202530Every
Annual inspection checklist (see below) — Performyear
Engine oil — change (Kawasaki 10W-40 engine oil)year
Oil filter — replace (HF123)
Air cleaner element — clean
Air cleaner element — replace5 cleanings
Spark plug — clean and gap, replace if necessary (NGK DP9EA-9)
Valve clearance — check
Fuel system — check
Cylinder head bolts — check
Brake fluid — change (Castrol DOT 4)2 years
Nuts, bolts, and fasteners — check
Radiator hoses, connections — checkyear
Swing arm pivot — lubricate
Brake camshaft — lubricate2 years
Steering stem bearing — lubricate2 years
Front fork oil — change
Coolant — change (ethylene glycol pre-mix, e.g. Zerex G05)2 years
Caliper piston seal and dust seal — replace2 years
Master cylinder cup and dust seal — replace2 years
Brake hoses — replace4 years
Fuel hoses — replace4 years
Drive chain — lubricate (Motul chain paste)400 mi (600 km)
Drive chain slack — check
Target 20-35 mm (0.8-1.4 in)
600 mi (1000 km)
Kawasaki KLR250 maintenance schedule table

Kawasaki KLR250 annual inspection checklist

Kawasaki KLR250 Annual Inspection Checklist
Battery electrolyte level — check (every month when not riding)
Brake fluid level — check (pre-ride)
Drive chain wear — check
Spark arrester — clean
Idle speed — check
Throttle grip play — check
Evaporative emission control system — check (if fitted)
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
Tire wear — check
General Lubrication — perform
Kawasaki KLR250 Annual Inspection Checklist

Tire size and tire pressure for the Kawasaki KLR250

The Kawasaki KLR250 has a 21-17 tire combo. Stock it shipped with Dunlop trail tires, but you can fit anything that fits the following tire sizes.

WheelTire sizeTire pressure (cold)
Front3.00-21 4PR150 kPa/21 psi
Rear 4.60-17 4PR150-175 kPa kPa/21-25 psi, depending on load
Tire sizes and pressures, KLR250

About the Kawasaki KLR250

The KLR250 is a lightweight dual sport motorcycle, made with simple specs and intended to be used in a variety of conditions, ranging from road work to off-road, but not singularly focused on either.

It’s 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 counter-balancers keep the powerplant running smoothly 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 (occasionally).

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

The KLR250 originally came with universal tires. These days they’d do well with trail or dual sport tires, whatever suits your riding conditions.

The KLR250 has a front disc and a rear drum.

Reference, 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.

Similar Posts

0 0 votes
Article Rating
Notify of
Inline Feedbacks
View all comments