Kawasaki KL 250 (1977-1978): A Timeless Dual-Sport Legacy Revisited

Introduction

The Kawasaki KL 250, produced between 1977 and 1978, represents an era when motorcycles began transitioning from purely utilitarian machines to versatile companions for both pavement and dirt. As one of Kawasaki’s early forays into the dual-sport segment, the KL 250 carved out a reputation for reliability, simplicity, and approachable performance. Decades later, this air-cooled workhorse still resonates with riders who value mechanical honesty and nostalgic charm. Let’s take this vintage warrior for a spin and explore why it remains a beloved classic.

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Design: Form Follows Function

The KL 250’s design is a masterclass in no-nonsense engineering. Its steel frame, high-mounted fenders, and upright riding position scream “adventure-ready,” even by today’s standards. The chrome-accented fuel tank, minimal bodywork, and squared-off seat give it a rugged, utilitarian aesthetic that’s aged surprisingly well.

At 135 kg (298 lbs), the KL 250 feels featherlight compared to modern dual-sports. The slim profile and narrow seat make it easy to maneuver, whether you’re threading through city traffic or picking your way down a rocky trail. The analog speedometer and basic switchgear keep the cockpit refreshingly simple—no touchscreens or ride modes here.

While the suspension setup is rudimentary (a telescopic fork up front and dual shocks at the rear), it’s perfectly suited for the bike’s intended use. The 18-inch rear and 21-inch front wheels, wrapped in period-appropriate knobby tires, strike a balance between on-road stability and off-road agility.

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Engine and Performance: Air-Cooled Authenticity

Specs at a Glance:
- Engine: 246cc air-cooled single-cylinder
- Power: 17 PS (13 kW)
- Torque: Not specified, but expect ~20 Nm (14.7 lb-ft)

Firing up the KL 250’s single-cylinder engine is an exercise in sensory nostalgia. The carbureted motor barks to life with a throaty, mechanical growl, settling into a lumpy idle that vibrates through the pegs and handlebars. Throttle response is immediate but manageable, thanks to a cable-operated slide carburetor that delivers fuel with old-school precision.

On the road, the 17 PS (13 kW) powerplant feels adequate rather than exhilarating. Top speed hovers around 110 km/h (68 mph), but the engine thrives in the midrange, making it ideal for backroad cruising or climbing dirt trails. The 5-speed transmission shifts with a satisfying clunk, and the cable-actuated clutch requires a firm hand—no hydraulic assist here.

Where the KL 250 truly shines is off-road. The torquey low-end power lets you chug up steep inclines without stalling, while the light weight ensures you can manhandle the bike through tricky terrain. Air cooling keeps things simple, though prolonged slow-speed riding on hot days can lead to noticeable heat soak near the rider’s legs.

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Handling: Lightweight Agility Meets Vintage Limits

Swing a leg over the KL 250, and you’ll immediately appreciate its narrow seat and neutral ergonomics. The handlebars are wide and upright, offering leverage for off-road maneuvers without straining your wrists on pavement. The bench seat is firm but surprisingly comfortable for shorter rides.

On asphalt, the KL 250 feels stable at moderate speeds, though crosswinds and truck blasts can push it around due to its light weight. The drum brakes—mechanical at both ends—require deliberate lever pressure. Stopping distances are… leisurely by modern standards. (Pro tip: Plan ahead and embrace the pace of 1970s braking technology.)

Off-road is where the KL 250’s geometry comes alive. The long-travel suspension (for its time) soaks up ruts and rocks, while the high ground clearance lets you tackle moderate obstacles without scraping the undercarriage. Tire pressure recommendations (1.5 bar front / 1.8 bar rear; 22 psi / 26 psi) strike a reasonable compromise for mixed-surface riding.

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Competition: How Does the KL 250 Stack Up?

In the late ’70s dual-sport arena, the KL 250 faced stiff competition:

1. Yamaha DT250:
2. Lighter (128 kg) and slightly more powerful (21 PS)
3. Better suspension for aggressive off-roading

4. KL counters with superior low-end torque and durability

5. Honda XL250:

6. Legendary Honda reliability and smoother power delivery
7. Six-speed transmission (vs. KL’s five-speed)

8. KL wins on parts affordability and ease of maintenance

9. Suzuki TS250:

10. Two-stroke engine offers sharper acceleration
11. Higher maintenance demands and smoky exhaust
12. KL’s four-stroke is better suited for daily commuting

Verdict: The KL 250 wasn’t the fastest or most advanced in its class, but its balanced performance and bulletproof construction made it a favorite for riders who valued practicality over peak performance.

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Maintenance: Keeping the Legend Alive

Owning a 45+ year-old motorcycle requires diligence, but the KL 250’s simple design makes it a DIY dream. Here are key considerations:

Valve Adjustments

• Intake: 0.08–0.13 mm (0.003–0.005 in)
• Exhaust: 0.17–0.22 mm (0.007–0.009 in)
  Check every 3,000 km (1,864 miles). Use MOTOPARTS.store’s feeler gauge kit (#MP-FG6) for precise measurements.

Oil Changes

• Without filter: 1.1L of SAE 20W-40
• With filter: 1.4L
  We recommend MOTOPARTS Premium 20W-40 Mineral Oil (#MP-4T20W40) for its zinc additive protection.

Chain Care

The 96-link chain and 14/40 sprocket combo requires regular lubrication. Our High-Adhesion Chain Lube (#MP-CL500) reduces fling while protecting against rust.

Brake Maintenance

Drum brakes demand periodic cleaning to remove dust and debris. Upgrade stopping power with MOTOPARTS.store’s Organic Brake Shoes (#MP-DBS250), which offer better bite than original asbestos-lined units.

Spark Plugs

Stock NGK BR7ES plugs work fine, but consider the iridium NGK BR7EIX (#MP-SPIR250) for colder starts and longer service intervals.

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Conclusion: Why the KL 250 Still Matters

The Kawasaki KL 250 isn’t about cutting-edge tech or blistering speed—it’s about reconnecting with motorcycling’s raw, unfiltered essence. Riding one today is a reminder that adventure isn’t defined by horsepower figures or electronic aids, but by the willingness to explore.

For owners looking to preserve or restore these classics, MOTOPARTS.store offers everything from period-correct decals to performance upgrades. Whether you’re rebuilding the carburetor or prepping for a vintage enduro event, we’ve got the parts to keep your KL 250 running for another four decades.

Throttle down, kickstart up, and let the trail decide where you’re headed next.

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Specifications sheet

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