Friday, April 16, 2010

Kawasaki KLR250 Parts Diagrams

Kawasaki KLR 250 Parts Diagrams SchematicsThe only thing worse than buying a used bike and finding that its missing parts is not being able to figure out exactly which parts are missing or how they install on the bike. That's where parts diagrams come in handy. Thankfully Kawasaki has released the parts diagrams for the KLR250 to the public so anyone can see how their bike is supposed to be assembled. Below you'll find all the part diagrams for the Kawasaki KLR250. Some part numbers may have changed from year to year so its best to check with your local dealer before order parts for your bike.

Kawasaki KLR 250 Parts Diagrams
-Airbox and Air Filter
-Balancer Assembly
-Brake Pedal
-Cables
-Camshafts and Tensioner
-Carburetor
-Chassis Electrical
-Clutch
-Crankcase
-Crankshaft
-Cylinder Head
-Cylinder and Pistons
-Emissions Equipment
-Engine Covers
-Exhaust System
-Fenders
-Foot Pegs
-Forks
-Frame 1
-Frame 2
-Front Brake
-Front Hub
-Fuel Tank
-Gauges
-Generator
-Handlebars
-Headlight
-Ignition Switch
-Ignition System
-Kick Starter
-Master Cylinder
-Oil Pump
-Radiators
-Rear Shock
-Rear Hub and Brake
-Rear Suspension
-Seat
-Shift Forks and Drums
-Shifter
-Side Covers
-Side Stand
-Swingarm
-Tail Light
-Tool Bag
-Transmission
-Turn Signals
-Valve Cover
-Valves
-Water Pump
-Wheels and Tires

Imaged Source: Kawasaki

51 comments:

  1. What is part#16097 called? Thanks.

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  2. 16097 is the oil strainer assembly, also known as the oil pump filter screen. It is meant to filter out large particles from the oil before it reaches the oil pump. It's a good idea to check it if you haven't already. Some klr250 and klr650 owners have reported finding a ton of debris clogging the screen.

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    1. Re: 1/4" Vacuum Line (Part #95059B) located behind choke cable. This vacuum line is missing from my 1991 non-california bike. What does it connect to on the other end? Thanks!

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  3. Can you point where you see that part number? I don't see it on the diagrams.

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    1. Sorry. It's #92059B on the carb diagram. Thanks.

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  4. Oh ok, 92059B is the carb vent line. It runs toward the back of the bike to a bracket right in front of the wheel. You'll probably find the float bowl drain and coolant overflow lines going to the same place.

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  5. Very good, thanks! I'm familiar with the area. There's also an air box drain thru the bracket. Actually the coolant overflow is routed under the seat to the rear fender to keep from overflowing in the path of the rear tire.

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  6. Accidently backed out the idler pulley bolt too far and can't get it back in. Anyone have any ideas on how to realign the pulley without tearing the head down? See Camshafts and Tensioner Breakdown - Part #39115

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  7. That's a tough one. You *might* be able to take the valve cover off and get something in there to move the idler back in place. I haven't been in there in a while so I can't remember if there is any room.

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  8. whats the procedure to replace swing arm protector part no 55020.

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    1. Unfortunately you've got to remove the swingarm to get the new protector on. You'll need to figure out a way of supporting the frame of your bike so you can unbolt the swingarm and slide the new protector in place.

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    2. thanks mike for prompt reply and for this great informative site keep up the good work cheers.

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  9. in specifactions it states my aussie 1989 klr makes 24hp yet US model makes 28 why the differance.

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    1. It's most likely due to different camshaft profiles.

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    2. thanks for this answer as well. All so may I inform other klr250 owners to be aware that after some years the air duct from air box to carby tends to harden and shrink then can slip off carby and allow dirt into motor happened to mine, recently saw 2 other bikes with same problem. Also I found air filter cover distorts over time letting in dirt I solved this by making steel backing plate hope this info may stop some ones pride & joy getting sick like mine did.

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  10. Hi dude i'm caling from Malaysia, i have 2 unit the kawasaki KLR 250 & year 2001 model...i'm buying from military government tender in malaysia.
    and what I want to share with you, can i convert other spare part the new model kawasaki KLX250 to KLR250 .

    examples as:
    1.the rear rim and disc brake.
    2.all cover set KLX250 to KLR250..like new :)
    3.carburetor "i think this is same model" (Keihin CVK34)
    4.digital meter.
    5.Front suspension KLX to KLR.

    thank you for giving me a chance question..

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    1. Aizat, Most parts from the KLX and the KLR aren't interchangeable. You are correct, the carb will probably swap over though it would need to be rejetted. The front suspension probably won't work unless you were to swap the entire front section (forks, wheel, brakes, etc) from the KLX.

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    2. BTW If you want to see what, if any, parts are the same on the KLR and the KLX you can cross reference the part numbers on the part diagrams section of Kawasaki.com

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    3. what is most important can i swap the rear hub without replace the swing arm (plug & Play)? because i interested the disc model replace with drum brake..just want to share experiences knowledge from u

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    4. anything thanks mike for answering my question...

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  11. No unfortunately the whole rear end is different so it won't swap over.

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  12. just rebuilt the carb on my 250 and for some reason it won't start. checked all the hoses for clogs and even pulled my carb again and sprayed it down with cleaner just in case. any suggestions?

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  13. Check to make sure the slide diaphragm isn't pinched under the top cover or torn. Also make sure the carb to engine and airbox to carb connections are tight, any air leaks will make it nearly impossible to start.

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  14. HELP HELP!!! Where can i find a set of used front forks for a 03 klr 250? please email me if anyone knows. Thanks so much. bgkkak@comcast.net

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  15. how to adjust the camshaft tensioner? do you need to set the dots on the gearwheels in line.

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    1. Sander, the KLR250 camshaft tensioner isn't adjustable. Some say you can remove it and replace it and in doing so the spring will re-tension but in my experience that is more likely to hurt an old tensioner more than help. If you really think it is worn out then just replace it with a new one. They aren't cheap but at least you won't have to worry about it anymore.

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  16. Hi Mike I had my klr250 top end rebuilt 3 years ago ran it in as owners manual stated but it has always used oil lately it blows a fair bit of smoke after cold start,valve stem seals were replaced during rebuid, could it be that the rings failed to seat properly from riding it to easy from start,may be i should have ridden it hard instead, what do you think Mike

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    1. It only blows smoke when cold? Are you certain it is oil and not smoke from being rich? If it is oil smoke then I'd say something probably wasn't done correctly during the rebuild, possibly inncorect rings or rings that weren't placed on the pistons correctly. Unfortunately it is impossible to say for sure without tearing it apart.

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    2. Something that just came to mind, there is a crankcase breather tube that goes from the engine to the airbox. In the airbox there is a small hole that can get clogged and that could result in too much pressure in the crankcase and smoking. Is it the problem? Probably not, but it's worth a look.

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    3. Hi mike i checked breather no blockage,also checked valve clearance found cam chain loose, took out tensioner found plunger all most fully extended only 3mm adjustment left seems to me chain must be badly stretched,what is your opinion mike,should i get chain replaced also should i replace tensioner as well as plunger pushes back in with finger pressure and lastly would loose cam chain have any effect on blowing oil smoke at start up.

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    4. A loose timing chain shouldn't make it burn oil, though it would definitely make it run sluggish. I would definitely have it looked at though because on these bikes a bad chain or tensioner could cause major engine problems. Whoever you have look at it make sure they also check the cam chain guides inside the case because I believe that can also contribute to the chain being loose.

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    5. Thanks Mike I will get my mechanic to check it all out.

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    6. Hi Mike I took my klr 250 apart today to do cam chain, guides ok,then i noticed main crank bearing loose in crankcase even turns,is that normal for these bikes, i thought they should be a tight press fit in case.

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    7. I'm not certain how loose the bearings should be in the case but I doubt they should be that loose. When I get a chance I'll check my service manual and see if there are any specs for that

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    8. I checked the manual but unfortunately there isn't much mention about the bearing fitment that I could see. It does mention using a press to install new bearings and seals but I'm not certain it is required. From my experience the bearings don't usually spin freely like that. Wish I could be more help.

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  17. thanks from argentina i try to restore a klr 250 ´96.actually between restore and modify to a street tracker because all plastics been missed and here its impossible to buy it. your blog has been very helpfull, thanks again

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  18. Hi where can i find the code parts names ?????? plz answer me :P :D

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    1. Go on BikeBandit.com and look up your bike on their parts finder. It uses these same diagrams with all the part titles.

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  19. after riding on an moto x track and tking jumps head light tail light wont come on with key turned on and will not crank starter, will push start and run fine ?//

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  20. How do you repair/remove a clutch plate of an KL250A kawasaki engine?Where is it in the engine?thanks!

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    1. On the KLR it is behind the right engine cover. If you are unsure, just follow the clutch cable, where it stops is where the clutch is. Usually you have to remove the cable, shift fork, and side cover.

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  21. Is the front wheel Hub the same for KLR 250 and KLR 650?

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  22. hola tenes idea si el tornillo (132) es pasante de aceite o es ciego?

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  23. hola tenes idea si por el tornillo (132) pasa el aceite? es agujereado o pasa a través de la rosca?

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  24. hello I am looking for party number 13128, I will appreciate if you can help me to find one, email me grocora@gmail.com

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    1. Your only option may be to keep an eye on ebay for transmission parts. There are quite a few transmission internal parts sets up there right now that have the output shaft.

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