There were two KLX250s in 1994 - the plastic tanked enduro version, and the compliance-plated, steel tanked trail version.
I owned both, at the same time. Well my complianced one was a slightly later 300. The only real difference apart from a bit more weight on the complianced one was the enduro had a steeper steering angle and turned a bit quicker. But riding them both back to back in the bush, I never noticed much difference between them.
Tests at the time also mentioned:
steel vs plastic tank,
steel, sealed, non-adjustable vs alloy, rebuildable, externally adjustable shock,
CV vs pumper carb,
non-adjustable vs double adjustable forks;
e-start vs kick-start,
ADR crap vs no ADR crap.
There may have been other things that I can't remember without checking - stuff like less suspension travel, different muffler, extra junk on the frame, rubber coated footpegs, etc.
Are you sure your not mixing it up with the KLR 250 that was the soft road trail version. My enduro KLX came with the CV carb. The forks only have one adjustment, and the trick in the day was to put KX forks into it. Apart from the steel tank and ADR gear there wasn't much difference between my two KLX's. The KLR was a world apart with rubber pegs, etc like you mention.
Nope. The older KLR ran from 1984, and is, as you say, a totally different bike.
Through the late 1980s and into the 90s, Kawasaki was big fans of making multiple versions of the same bikes: a decent (or better) enduro bike, and a watered down road legal version (KLX250 & 650, KDX200 and 250).
It probably made sense internationally, but it was a dumb move in Australia.
Apparently KHI specifically stopped Kawasaki Australia from making the Enduro versions road legal, which nobbled all of the bikes in the marketplace.
IIRC, there were actually three versions of the KDX250 - ok, lame and really lame.
In the case of the KLX, the KLX250R would have demolished the XR and first generation TTR, if only they were registerable...
I'm away from my ADB stash ATM, but I will post stuff up when I get home.