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Kawasaki KLX250S 2010 Full Service Repair Manual

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The 2010 KLX250S is a versatile dual-sport motorcycle designed for riders who demand capability on varied terrain, from city streets to off-road trails. Building on a strong lineage of off-road...
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Kawasaki KLX250S 2010 Full Service Repair Manual
The 2010 KLX250S is a versatile dual-sport motorcycle designed for riders who demand capability on varied terrain, from city streets to off-road trails. Building on a strong lineage of off-road motorcycles, this model offers a lightweight and agile platform, powered by a liquid-cooled, 4-stroke, 249 cc engine with digital fuel injection. Its design philosophy emphasizes a balance of performance and rider-friendly handling, making it a popular choice for both commuting and adventure riding. The KLX250S is engineered for reliability and ease of use, embodying a commitment to quality in the dual-sport segment. This comprehensive English-language service manual provides in-depth guidance for the maintenance, repair, and restoration of your 2010 KLX250S. It covers all major systems, including the engine, fuel system, transmission, chassis, electrical system, brakes, and cooling system, offering detailed procedures for everything from routine oil changes and filter replacements to complete engine and transmission rebuilds. Additionally, the manual includes troubleshooting charts for common issues, technical specifications, and safety guidelines, empowering owners and technicians to effectively maintain and service the motorcycle, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250S
Year:
2010
👋 Introduction
Market Position
Segment:
Dual-sport/Enduro motorcycle
Target Audience:
Riders seeking off-road capability and street legality, DIY enthusiasts
Competitive Analysis
Competitors:
Honda CRF250L, Yamaha WR250R
Key Features
Design Philosophy:
Lightweight, agile, capable on varied terrain
Manual Value Proposition:
Empowers owners with comprehensive knowledge for maintenance and repair, saving time and money
📋 Manual Details
Coverage Areas
Manual Type:
Full Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, tuning, and diagnostics
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body
Transmission:
Clutch, gearbox, gear shifting mechanism, lubrication
Chassis:
Frame, swingarm, suspension (front and rear), steering system
Electrical System:
Ignition system, charging system, lighting, instrumentation, starter motor, ECU
Brakes:
Front and rear brake systems, hydraulics, caliper service, pad replacement
Cooling System:
Radiator, fan, coolant flow, thermostat
Exhaust System:
Exhaust pipe, muffler, catalytic converter (if applicable)
Wheels And Tires:
Wheel bearing service, tire replacement, spoke tensioning
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment
Troubleshooting:
Diagnostic charts, fault finding for common issues
Repair:
Step-by-step repair instructions for all major components
Rebuild:
Detailed instructions for engine and transmission rebuilds
Restoration:
Guidance on refurbishing and restoring the motorcycle
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and electrical system rebuilds
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval
Print Quality
Resolution:
High-resolution diagrams and text for clarity
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve single
Displacement:
249 cc
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Performance
Horsepower Peak:
Approx. 22.7 HP @ 8,000 rpm (stock, may vary)
Torque Peak:
Approx. 17.7 lb-ft @ 6,500 rpm (stock, may vary)
Fuel System
Fuel Delivery:
Digital Fuel Injection (DFI) with Keihin 34mm throttle body
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
Digital CDI with electronic advance
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-disc
Features
Final Drive:
Sealed chain
Transmission Fluid Type:
API GL-4, SAE 80W or 90W hypoid gear oil (check manual for exact spec)
📐 Dimensions
Exterior
Overall Length:
86.8 in (2,205 mm)
Overall Width:
32.1 in (815 mm)
Overall Height:
49.8 in (1,265 mm)
Wheelbase:
57.3 in (1,455 mm)
Weights
Curb Weight:
Approx. 291.1 lb (132 kg)
Fuel Capacity:
2.0 US gal (7.7 L)
Suspension
Front Suspension Travel:
11.0 in (280 mm)
Rear Suspension Travel:
10.0 in (255 mm)
Wheels And Tires
Front Tire:
80/100-21 M/C 51P
Rear Tire:
100/100-18 M/C 59P
Front Wheel Size:
21 x 1.60
Rear Wheel Size:
18 x 2.15
Wheelbase:
1,455 mm (57.3 in)
🛡️ Safety Features
Ratings
Safety Certification:
Not applicable (Motorcycle)
Active Features
Braking System:
Front: 250mm petal disc; Rear: 240mm petal disc
ABS:
Not available on this model
Passive Features
Lighting:
Halogen headlight, LED taillight
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation)
Driver Assistance
ABS:
Not equipped
Connectivity
Bluetooth:
Not equipped
Instrumentation
Dashboard Features:
Digital speedometer, analog tachometer, odometer, trip meter, clock, fuel gauge, indicator lights
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 6 months (refer to manual for exact intervals based on usage)
Air Filter Cleaning:
Every 4,000 miles (more frequently in dusty conditions)
Spark Plug Replacement:
Every 7,500 miles
Valve Clearance Check:
Every 15,000 miles
Chain Lubrication Adjustment:
Every 600 miles or as needed
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (JASO MA recommended)
Engine Oil Capacity:
1.7 L (1.8 US qt) with filter change
Coolant Type:
High-quality ethylene glycol-based coolant, 50% solution with distilled water
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, brake pads
Fuel System Maintenance:
Occasional cleaning of fuel injectors and throttle body may be beneficial
Part Numbers
Oil Filter Part Number:
e.g., 16099-004 (verify with manual)
Air Filter Part Number:
e.g., 11013-0020 (verify with manual)
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Longstanding manufacturer of performance motorcycles with a strong off-road lineage
Model Evolution
Klx Lineage:
The KLX series has a history of dual-sport and off-road motorcycles, with the 250cc platform being a long-standing offering, evolving with fuel injection and improved components over generations.
Production
Manufacturing Location:
Japan
Key Year Updates:
The 2008 model year introduced significant updates including fuel injection and a more powerful engine for the KLX250S.
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
Not specifically listed for 2010 model, but KLX series generally praised for versatility and value.
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