Kawasaki KLX250S 2009-2010 All Service Manual Repair

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Tipo: Motorcycle

Proveedor:

SKU: 79893

Etiquetas: 2009 2010 Kawasaki KLX250S Misc Motorcycle Motorcycles

Variantes de producto

Descripción

The KLX250S, produced for the 2009 and 2010 model years, is a versatile dual-sport motorcycle renowned for its lightweight, agile design, and capable off-road suspension. It features a liquid-cooled, DOHC, four-valve, single-cylinder engine displacing 249 cc, delivering a balance of power suitable for both trail riding and commuting. Known for its user-friendly nature and reliable performance, the KLX250S offers a compelling package that excels in various riding conditions, making it a popular choice among enthusiast riders. This comprehensive Factory Service Manual (FSM) provides in-depth coverage for the maintenance, repair, and servicing of the KLX250S (chassis code KLX250S, engine code prefix LX250F) for 2009-2010 models. It details engine mechanicals, fuel and ignition systems, cooling, lubrication, transmission, suspension, braking, and electrical systems. The manual includes routine maintenance procedures, troubleshooting guides, engine rebuild instructions, and technical specifications, serving as an essential resource for owners and technicians to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250S

Model Years Covered:

2009, 2010

Codes

Chassis Code:

KLX250S

Engine Code Prefix:

LX250F

👋 Introduction

Market Position

Segment:

Dual-sport/Off-road motorcycle

Target Audience:

Enthusiast riders, DIY mechanics, and service technicians.

Competitive Analysis

Competitors:

Honda CRF250L (later model), Yamaha WR250R, Suzuki DR-Z250.

Klx250S Advantage:

Known for its user-friendly nature, capable off-road suspension, and reliable engine, making it a popular choice for trail riding and commuting.

Key Features

Design Philosophy:

Lightweight, agile, and versatile for both on-road and off-road use.

Engine Configuration:

Liquid-cooled, DOHC, four-valve, single-cylinder engine.

📋 Manual Details

Coverage Areas

General Coverage:

Complete service, repair, and maintenance for Kawasaki KLX250S models 2009-2010.

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, troubleshooting, and repair of all internal and external components.

Fuel System:

Carburetor (Keihin CVK34) tuning, disassembly, cleaning, repair, and adjustment.

Ignition System:

CDI ignition system, spark plug specifications, troubleshooting, and testing.

Cooling System:

Radiator, fan, thermostat, coolant specifications, and bleeding procedures.

Lubrication System:

Oil pump, oil passages, oil filter specifications, and oil change procedures.

Transmission:

Clutch operation, gearbox disassembly, assembly, inspection, and maintenance.

Suspension Front:

Inverted telescopic fork service, oil levels, seal replacement, and adjustments.

Suspension Rear:

Uni-Trak rear suspension, shock absorber service, linkage maintenance, and adjustments.

Braking System:

Hydraulic disc brakes (front and rear), caliper service, master cylinder, fluid specifications, bleeding procedures, and pad replacement.

Electrical System:

Wiring diagrams, lighting, charging system (stator, regulator/rectifier), battery specifications, starter motor, and fuse box.

Frame And Bodywork:

Frame inspection, handlebars, seat, fuel tank, fenders, and all body panel removal/installation.

Wheels And Tires:

Wheel bearing service, spoke tensioning, tire replacement, and pressure specifications.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning/replacement.

Troubleshooting Guides:

Diagnostic procedures for common and uncommon issues with detailed symptom-cause-remedy charts.

Engine Rebuild:

Complete procedures for cylinder head removal/installation, piston and ring replacement, crankshaft and connecting rod service.

Suspension Overhaul:

Detailed instructions for fork seal replacement, shock absorber servicing, and linkage bearing maintenance.

Carburetor Tuning:

Jetting adjustments, idle speed settings, pilot screw adjustments, and float bowl level checks.

Electrical Diagnostics:

Step-by-step testing of charging system, ignition system, lighting circuits, and starter system.

Brake System Maintenance:

Bleeding procedures, pad replacement, caliper piston service, and master cylinder rebuild.

Technical Depth

Depth:

Comprehensive from basic adjustments and fluid changes to complete engine and transmission overhauls.

Detail Level:

Highly detailed with exploded views, torque specifications, and special tool requirements.

📊 Manual Specifications

File Format

File Format:

Searchability:

Fully searchable text content for quick information retrieval.

Print Quality

Print Quality:

High-resolution scans of original factory manual pages.

Image Clarity:

Clear, legible diagrams and photographs.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, four-valve, single-cylinder

Displacement:

249 cc (250 cc class)

Bore X Stroke:

72.0 x 61.2 mm

Compression Ratio:

11.0:1

Cooling Method:

Liquid-cooled

Performance

Horsepower Est:

Approximately 20-24 hp @ 7000 rpm (varies with emissions equipment and region)

Torque Est:

Approximately 15-18 lb-ft @ 6000 rpm (varies with emissions equipment and region)

Fuel System

Fuel Delivery:

Carburetor: Keihin CVK34 with accelerator pump

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

2.4 US gallons (9.1 L)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

Detailed gear ratios available in manual (e.g., 1st: 2.643, 2nd: 1.933, 3rd: 1.556, 4th: 1.333, 5th: 1.150, 6th: 1.000)

Transmission Fluid:

Refer to manual for specific type and capacity (typically motorcycle-specific gearbox oil).

📐 Dimensions

Exterior

Length:

86.8 in (2205 mm)

Width:

32.1 in (815 mm)

Height:

49.8 in (1265 mm)

Wheelbase:

56.5 in (1435 mm)

Ground Clearance:

11.0 in (280 mm)

Seat Height:

34.8 in (885 mm)

Weights

Curb Weight Est:

286.6 lbs (130 kg)

Front Tire Size:

80/100-21M/C 51P

Rear Tire Size:

110/100-18M/C 64P

Wheel Type:

Spoked wheels

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety is assessed differently than automobiles; focus is on design, materials, and component quality covered in manual).

Active Features

Braking System Type:

Hydraulic disc brakes, front and rear.

Suspension Stability:

Inverted front fork and Uni-Trak rear suspension contribute to stable handling.

Passive Features

Lighting:

Halogen headlight, LED taillight, turn signals.

Ergonomics:

Designed for rider control and visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator).

Driver Assistance

Driver Assistance Features:

N/A (Motorcycle design focuses on rider control and mechanical feedback).

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles (4,800 km) or 6 months, whichever comes first (refer to manual for exact specification).

Air Filter Cleaning:

Every 3,000 miles (4,800 km) or as needed based on riding conditions.

Spark Plug Check:

Every 7,500 miles (12,000 km).

Valve Clearance Check:

Every 15,000 miles (24,000 km).

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 10W-40 motorcycle oil (refer to manual for exact specification).

Engine Oil Capacity:

1.7 US qt (1.6 L) without filter change; 1.8 US qt (1.7 L) with filter change.

Coolant Type:

Permanent type antifreeze coolant mixed with demineralized water (50/50 ratio).

Brake Fluid Type:

DOT 4 (refer to manual for exact specification).

Fork Oil Type Viscosity:

Kawasaki KHL15-10W or equivalent SAE 10W (refer to manual for exact specification).

Fork Oil Level:

Refer to manual for exact measurement (typically measured from the top of the fork tube with spring removed and fork compressed).

Known Issues

Carburetor Icng:

Carburetor can sometimes be prone to clogging if fuel is left stagnant for extended periods; regular use and fuel stabilizer recommended.

Cam Chain Tensioner:

Some owners report the automatic cam chain tensioner can become noisy over time, potentially requiring manual adjustment or replacement. The manual will detail inspection and adjustment procedures.

Suspension Seals:

Like many motorcycles of this era, fork seal leaks can occur with heavy off-road use. The manual provides detailed instructions for seal replacement.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments.

Model Evolution

Klx Lineage:

The KLX line has a history dating back decades, evolving from smaller displacement dirt bikes to more versatile dual-sport machines like the KLX250S.

Klx250S Design:

The 2009-2010 models represent a refinement of the KLX250 platform, often featuring updated styling and emissions compliance compared to earlier generations.

Production

Manufacturing Location:

Typically manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

Often praised in reviews for its balance of off-road capability and on-road manners, making it a versatile package for its class.

Ratings

Durability Reputation:

Generally considered a durable and reliable motorcycle with proper maintenance, as detailed in this service manual.

Certifications

Emissions Compliance:

Models are designed to meet emissions standards for their respective markets for the specified years, with details on adjustments in the manual.