Kawasaki KLX250SA 2010 Workshop Service Repair Manual

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Stichworte: 2010 Kawasaki KLX250SA Misc Motorcycle Motorcycles

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Beschreibung

The 2010 KLX250SA is a versatile dual-sport motorcycle designed for both on-road commuting and off-road adventures. Known for its lightweight maneuverability and robust engine, this model offers a balanced performance that appeals to a wide range of riders. The extensive off-road heritage is evident in the KLX250SA's durable construction and reliable performance, making it a capable companion for exploring diverse terrains. Its design prioritizes usability and a comfortable riding experience, whether navigating city streets or tackling trails. This comprehensive workshop service repair manual provides factory-level technical detail for the 2010 KLX250SA. It covers all essential aspects of maintenance, repair, and troubleshooting for every major system, including the engine, fuel system, transmission, brakes, suspension, and electrical components. With step-by-step procedures, detailed specifications, and clear wiring diagrams, this manual is an indispensable resource for owners and technicians aiming to keep the KLX250SA in optimal condition and ensure its longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250SA

Year:

Motorcycle Type:

Dual-Sport / Off-Road

Generation

Generation Code:

KLX250 (SF/S/D-Tracker)

👋 Introduction

Market Position

Segment:

Lightweight dual-sport motorcycle, popular for trail riding, commuting, and light off-road use

Competitive Analysis

Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250

Key Features

Versatility:

Capable on both pavement and unpaved roads, offering a balance of performance and usability

Reliability:

Known for its robust engine and durable construction, common in Kawasaki's off-road lineage

Maneuverability:

Lightweight chassis and manageable power delivery contribute to excellent handling

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete Factory Service Repair

Page Count

Estimated Page Count:

Hundreds of pages (exact count not specified, but implied to be comprehensive)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Full disassembly, assembly, tuning, troubleshooting, specifications

Fuel System:

Carburetor (CVK34), fuel pump, fuel lines, fuel tank maintenance and repair

Ignition System:

CDI, spark plug, ignition coils, timing

Cooling System:

Liquid cooling system, radiator, fan, coolant specifications

Transmission:

Clutch, gearbox, shift drum, internal components, lubrication, troubleshooting

Drivetrain:

Chain drive, sprockets, maintenance and replacement procedures

Chassis Frame:

Frame inspection, alignment, related components

Suspension Front:

Telescopic front fork, damping adjustment, oil change, seal replacement, troubleshooting

Suspension Rear:

Uni-Trak rear suspension, shock absorber, linkage components, adjustment, maintenance

Brakes Front:

Hydraulic disc brake, caliper, master cylinder, brake pads, fluid, bleeding, rotor specifications

Brakes Rear:

Hydraulic disc brake, caliper, master cylinder, brake pads, fluid, bleeding, rotor specifications

Wheels Tires:

Wheel bearing maintenance, spoke tension, tire pressure, specifications

Electrical System:

Battery, charging system (stator, regulator/rectifier), lighting, starting system, wiring diagrams

Instrumentation:

Speedometer, tachometer, indicator lights, troubleshooting

Bodywork Trim:

Fairings, fenders, seat, fuel tank cover, decals, removal and installation

Exhaust System:

Muffler, head pipe, gaskets, inspection and repair

Troubleshooting:

Comprehensive diagnostic guides for all major systems, fault finding charts

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication

Repair:

Component disassembly, assembly, replacement, and adjustment for all major systems

Rebuild:

Detailed instructions for engine rebuilds, carburetor overhauls, and suspension rebuilds

Diagnostics:

Systematic troubleshooting steps and diagnostic flowcharts

Specifications:

Torque values, clearances, fluid capacities, electrical specifications, measurements

Wiring Diagrams:

Complete and detailed electrical system schematics

Technical Depth

Depth:

Factory-level technical detail for professional mechanics and advanced DIY enthusiasts

Detail Level:

Includes step-by-step procedures, exploded diagrams, and troubleshooting charts

📊 Manual Specifications

File Format

Format Details:

Searchable PDF, allowing easy navigation and printing of specific pages or the entire manual

Print Quality

Quality:

High-resolution scans, ensuring clarity of text and diagrams

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, 4-valve, Single-cylinder

Displacement:

249 cc (250cc class)

Bore X Stroke:

72.0 mm x 61.2 mm (typical for this generation)

Compression Ratio:

11.0:1 (typical)

Performance

Horsepower:

Approximately 22-24 HP @ 7,500 RPM (Estimate based on model year and configuration)

Torque:

Approximately 16-18 lb-ft @ 6,500 RPM (Estimate based on model year and configuration)

Fuel System

Carburetor:

Keihin CVK34 with Accelerator Pump

Fuel Capacity:

Approx. 2.5 - 3.0 gallons (7.7 - 11.0 Liters) depending on sub-model

Lubrication

Oil Capacity With Filter:

Approx. 1.6 - 1.8 Liters (Consult manual for exact specification)

Engine Oil Type:

API SG or SH, SAE 10W-40 motorcycle specific oil (Consult manual for exact specification)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-disc

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Length:

Approx. 85.2 inches (2165 mm) (Varies slightly by sub-model)

Width:

Approx. 33.5 inches (850 mm) (Varies slightly by sub-model)

Height:

Approx. 45.7 inches (1160 mm) (Varies slightly by sub-model)

Wheelbase:

Approx. 56.7 inches (1440 mm)

Ground Clearance:

Approx. 11.0 inches (280 mm)

Weights

Curb Weight:

Approx. 291 lbs (132 kg) (Varies slightly by sub-model)

Gross Vehicle Weight Rating:

Not explicitly specified, but typically around 350-400 lbs

Front Tire Size:

80/100-21 M/C 51P (Typical for KLX250S)

Rear Tire Size:

100/100-18 M/C 59P (Typical for KLX250S)

Wheel Bolt Pattern:

N/A (Spoked wheels with axle nuts)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not typically rated by organizations like NHTSA or IIHS)

Active Features

Braking System:

Disc brakes front and rear, hydraulic actuation

Not available on this model

Passive Features

Lighting:

Halogen headlight, LED tail light, incandescent turn signals

💡 Technology Features

Infotainment

Infotainment System:

N/A (Motorcycle, basic instrumentation only)

Driver Assistance

Rider Aids:

N/A (No electronic rider aids like traction control or ABS)

Connectivity

Connectivity Features:

Engine Technology

Fuel Injection Vs Carburetion:

Utilizes a carburetor (CVK34), which is detailed thoroughly in the manual for maintenance and troubleshooting.

Engine Cooling:

Liquid-cooled, a more advanced system than many air-cooled counterparts, improving performance and reliability. The manual covers its maintenance.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km or 3 months, whichever comes first (Consult manual for exact interval and conditions)

Air Filter Cleaning Interval:

Every 6,000 km or as needed in dusty conditions (Consult manual for exact interval)

Spark Plug Replacement Interval:

Every 12,000 km or as needed (Consult manual for exact interval)

Chain Maintenance Interval:

Lubricate and adjust chain every 1,000 km or as needed (Consult manual for exact interval)

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 (Consult manual for exact specification)

Coolant:

Kawasaki's Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water) (Consult manual for exact specification)

Fork Oil Type:

SAE 0W-20 or 10W (Consult manual for exact specification and volume)

Known Issues

Carburetor Performance:

Some users report lean conditions or flat spots, often addressed by rejetting or tuning the CVK34 carburetor, which the manual will detail.

Suspension Softness:

Stock suspension can be considered soft for aggressive off-road use, but the manual provides adjustment and rebuild procedures.

Cooling System Efficiency:

Proper coolant level and fan operation are critical, especially during sustained low-speed off-road riding. The manual covers checks and maintenance.

📚 Vehicle History

Brand Heritage

Kawasaki Off Road:

Kawasaki has a long and successful history in off-road motorcycling, including motocross and enduro racing, which informs the design of the KLX line.

Model Evolution

Klx Lineage:

The KLX250 has evolved over several generations, with the 2010 model representing a refinement of the design that emphasizes usability and off-road capability.

Sf Vs S:

The KLX250SA designation often refers to the standard 'S' model (dual-sport), while 'SF' models may feature different wheel configurations (e.g., 17-inch wheels for street). The manual likely covers variants of the KLX250.

Production

Manufacturing Location:

Primarily manufactured in Thailand for global markets.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 2010 KLX250SA might not be widely publicized, the KLX lineage consistently receives positive reviews for its all-around capabilities and value in the dual-sport segment.

Ratings

Owner Satisfaction:

Generally high owner satisfaction for its segment, valued for its durability and ease of maintenance.