2006 Kawasaki KLX 250 fork oil capacity

Capacity:
1.3L (when filter is not removed)
1.4L (when filter is removed)
1.5L (when engine is completely dry)
Level:
Between upper and lower levels

1. Yes, this is a major issue! Its not the shift drum cam unless its broken in half. It might be the shift forks, Won't go into any gear? Is there spring pressure in the shifter or does it flop? Is the shifter TIGHT on the shift shaft? I think its time for a professional to look at it.

REALLY... If you can't figure this out by simply looking at it.. .. TAKE IT TO A PROFESSIONAL!!!

Upside down
540 + 4 mL (completely dry)
Conventional
633 ± 4 mL (completely dry)

1. Oil plug gasket 2. clutch cover gasket, 3. Center case leaking
4. TOO much oil in crankcase, 5. Shift shaft seal. 6 Counter shaft seal.

If it has air caps on the top of the forks, you can put a little air in them. If not, the other thing you can do is add a bit more oil to each fork leg.

Depending on your size and weight, I would suggest that you obtain a set of KX65 forks, get the mod tripple clamps, and replace the whole front end. Its pricey but worth it.. look at fastminnis.com or any pitbike website for further information on klx110 mods. Good luck

SILKOLENE PRO RSF 5WT or use
SILKOLENE FORK OIL LIGHT
500-MLS OIL EACH LEG

The owners manual says to do the following if you don't want to remove the forks:
*raise the front wheel
*remove the fender, meter cable & unit, headlight, handle bar, fork protectors
*loosen the fork upper clamp bolts
*remove the caps from the top of the fork tube
*fully compress the fork tube so the dust cover touches the bottom and place a stand to hold it
*remove the springs
*set the oil level 68mm (standard) or 60 - 90 mm (adjustable) from the top of the tube

It may be easier to remove the tubes and you could replace the leaky seal at the same time. I did this recently and put in new springs too. It was my first time working on forks. With help from TT members and the service manual it was fairly easy. I didn't buy an oil gauge, seal driver, or spring holder. I used a ruler to measure the oil and a medicine dropper to remove any excess. For a seal driver I used a piece of PVC pipe cut in half then secured around the lower tube to drive the seal. Try a search on replacing fork seals for more info. 5w oil is standard but i have heard that 7 works well Good luck.